Sensitivity analysis and optimization of hot-stamping process of automotive components using analysis of variance and Taguchi technique

Abstract

Nowadays, the demand for achieving cars with higher strength, lower fuel consumption, and better safety considerations propels automakers to produce parts with extremely high strength-to-weight ratios. This criterion is done through the hot-stamping process considered as a novel technology employed for producing high-strength steel parts with low springback, particularly appropriate for the vehicle body. In this paper, firstly, numerical simulation of the hot-stamping process of a blank consisted of boron-alloyed steel 22MnB5 (with commercial name of Usibor 1500) is performed. Secondly, effects of different design parameters including blank holder force, die radius, gap between the punch and die, and forming time on the final temperature distributions as well as springback of the part is investigated. Consequently, optimization has been performed using Taguchi L16 orthogonal array to obtain the parameters which minimize above-mentioned parameters as two objective functions. Obtained results are verified based on performing numerical simulation and comparison to a similar work in the literature. Accuracy of the results is also assessed via the technique of plotting normal probability graphs of both objective functions. Finally, via evaluation of contribution percentage associated with analysis of variance considering each design parameter, a discussion is done by proposing the optimum design.