Robust design of energy absorbing components considering the manufacturing effects [Code 98441]

Abstract

Metal forming process involves many uncertainties that can compromise the safety and performance characteristics of the manufactured components. In this paper, the stochastic uncertainties associated with the material, process, and product are represented and propagated to process and performance responses. A finite element-based sequential coupled process-performance framework is used to simulate the forming and energy absorption responses of a thin-walled tube in a manner that both material properties and component geometry can evolve from one stage to the next for better prediction of the structural performance measures. Metamodeling techniques are used to develop surrogate models for rupture, thinning, springback, maximum crush force, mean crush force and mass. One set of metamodels relates the responses to the random variables whereas the other relates the mean and standard deviation of the responses to the selected design variables. A robust multi-objective optimization problem is formulated and solved to illustrate the methodology and the influence of uncertainties on manufacturability and energy absorption of a metallic double-hat tube. The results are compared with those of deterministic and augmented robust optimization problems. ©2012 AIAA.