Multi-Objective Optimization of TA1 Sheet Incremental Forming Based on ABAQUS Finite Element Simulation and NSGA-II

Abstract

Based on the Box-Behnken experimental design method and NSGA-II multi-objective optimization algorithm, combined with ABAQUS finite element simulation, this study optimizes and analyzes the four key parameters of the initial thickness, pitch, tool head diameter and bottom side length of the TA1 sheet single point incremental forming process. Firstly, the incremental forming model of truncated cone under ABAQUS environment is established, and the reliability of the model is verified by the experimental results of wall thickness. Taking the average wall thickness reduction rate (φ) and size error (ε) as the evaluation indexes of forming quality, the forming quality is significantly improved by optimization analysis. The results show that the optimized φ and ε are reduced by 8.22 % and 14.09 % respectively, which effectively improves the wall thickness uniformity and dimensional accuracy of the parts. In addition, the Pareto front solution set obtained in this study can provide a scientific basis for the engineering selection of TA1 sheet incremental forming process parameters.