Abstract:Combining the design of experiments (DOE) and three-dimensional finite element (3D-FE) method, a sequential multi- objective optimization of larger diameter thin-walled (LDTW) Al-alloy tube bending under uncertainties was proposed and implemented based on the deterministic design results. Via the fractional factorial design, the significant noise factors are obtained, viz, variations of tube properties, fluctuations of tube geometries and friction. Using the virtual Taguchi’s DOE of inner and outer arrays, considering three major defects, the robust optimization of LDTW Al-alloy tube bending is achieved and validated. For the bending tools, the robust design of mandrel diameter was conducted under the fluctuations of tube properties, friction and tube geometry. For the processing parameters, considering the variations of friction, material properties and manufacture deviation of mandrel, the robust design of mandrel extension length and boosting ratio is realized.

Key words: robust optimization; tube bending; uncertainty; aluminum alloy; multi-objective optimization