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Numerical Optimization of the Blank Dimensions in Tube Hydroforming Using Line-Search and Bisection Methods

机译：线搜索和二分法在管件液压成形中毛坯尺寸的数值优化

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The change from a consolidated manufacturing practice to a new solution is often a complex problem because of the operative limits of technologies and the strict constraints of industrial parts. Moreover, the new process must reflect or enhance the characteristics of the product and, overall, it must be more competitive in performances and costs. Accordingly, the development of a new process is a multilevel and multivariate problem that requires a systematic and hierarchical approach. The present paper focuses on the development of a Tube Hydroforming process capable to replace the current practice for production of T-Joint parts made of AISI 316L for the water pipes market. In particular, the problem must withstand many process and product constraints. Therefore, it was split in three steps focused on specific aspects of the process: identification of process parameters and configuration, numerical optimization of the blank tube dimensions (length and thickness), experimental tests and final improvements. In particular, two numerical methods were implemented in the optimization step: the line–search method to approach to the optimum point and Bisection method to refine the search. These approaches allowed us to identify the optimum process configuration and, in particular, the optimal dimensions of the blank tube that allows one to achieve the product requirements with the minimum cost of material.
机译：由于技术的操作限制和工业零件的严格限制，从合并的制造实践向新的解决方案转变通常是一个复杂的问题。而且，新工艺必须反映或增强产品的特性，并且总体上讲，它必须在性能和成本上更具竞争力。因此，新过程的开发是一个多层次，多变量的问题，需要系统和分级的方法。本文着重于开发一种管材液压成形工艺，该工艺能够替代当前生产用于水管市场的AISI 316L T型接头零件的实践。特别地，该问题必须承受许多过程和产品约束。因此，将其分为三个步骤，重点放在过程的特定方面：过程参数和配置的识别，空白管尺寸（长度和厚度）的数值优化，实验测试和最终改进。特别是，在优化步骤中采用了两种数值方法：接近最佳点的线搜索方法和优化搜索的对分法。这些方法使我们能够确定最佳的工艺配置，尤其是空白管的最佳尺寸，从而使人们能够以最低的材料成本实现产品要求。

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