Optimisation of a stamping process by a design of experiment linked to a modal analysis of geometric defects

The aim of this work was to present a method that gives an optimized set of values for the process parameters in order to obtain stamped parts with the fewest defects. The springback, influenced by process parameters, is one of the sources of defects. The process is simulated by the finite element method. A design of experiments is used to compute the mathematical model and to minimize the trials number. The defects are characterized by a set of modal shapes. A defect criterion is calculated from this decomposition. Then an optimisation is made by minimizing of this criterion in order to obtain the best process parameters. An example is shown in order to explain the method.