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Optimization of Stamping Process Parameters for Sustainable Manufacturing: Numerical Simulation Based on AutoForm

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  • Huiju Zhang

    (The Higher Educational Key Laboratory for Flexible Manufacturing Equipment Integration of Fujian Province, Xiamen Institute of Technology, Xiamen 361000, China
    State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an 710049, China)

  • Wenbo Wei

    (College of Engineering, Nanjing Agricultural University, Nanjing 210031, China)

  • Sifang Long

    (College of Biosystems Engineering and Food Science, Zhejiang University, Hangzhou 310058, China)

  • Manyi Zhou

    (Xiamen Swire Engine Service Co., Ltd., Xiamen 361021, China)

  • Chunhui Li

    (The Higher Educational Key Laboratory for Flexible Manufacturing Equipment Integration of Fujian Province, Xiamen Institute of Technology, Xiamen 361000, China)

Abstract

To address the increasing demand for sustainable manufacturing in the automotive industry, this study focuses on the optimization of stamping process parameters for heavy truck seat reinforcement plates. Finite element analysis software and AutoForm R7 were utilized to develop a numerical simulation model for the stamping process, aiming to enhance material utilization and reduce waste. The research aimed to predict forming defects and explore the effects of blank holder force, friction coefficient, and drawbead resistance coefficient on springback, wrinkles, and strain, with an emphasis on improving production efficiency and minimizing resource consumption. The forming quality was optimized through adjustments in blank holder force, friction coefficient, and drawbead resistance coefficient, demonstrating the potential for eco-friendly manufacturing. Multi-objective optimization was performed to identify the optimal parameter combination, achieving sustainable outcomes with improved forming precision and reduced material waste. Results revealed that the optimal parameter combination (A4B4C2) included a blank holder force of 500 kN, a friction coefficient of 0.18, and a drawbead resistance coefficient of 0.25. These settings minimized material thinning (11.6%), excessive thickening (7.4%), and springback (0.905 mm), aligning with sustainable production standards.

Suggested Citation

  • Huiju Zhang & Wenbo Wei & Sifang Long & Manyi Zhou & Chunhui Li, 2025. "Optimization of Stamping Process Parameters for Sustainable Manufacturing: Numerical Simulation Based on AutoForm," Sustainability, MDPI, vol. 17(1), pages 1-16, January.
    • Handle: RePEc:gam:jsusta:v:17:y:2025:i:1:p:341-:d:1560500
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    References listed on IDEAS

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    1. Luis Isasi-Sanchez & Jesus Morcillo-Bellido & Jose Ignacio Ortiz-Gonzalez & Alfonso Duran-Heras, 2020. "Synergic Sustainability Implications of Additive Manufacturing in Automotive Spare Parts: A Case Analysis," Sustainability, MDPI, vol. 12(20), pages 1-18, October.
    2. Wenshuai Wu, 2021. "A Revised Grey Relational Analysis Method for Multicriteria Group Decision-Making with Expected Utility Theory for Oil Spill Emergency Management," Mathematical Problems in Engineering, Hindawi, vol. 2021, pages 1-13, March.
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