Exploring the potential for a FEA-based design of experiments to develop design tools for bulk-metal joining processes

Hatherell, Jacob; Marmier, Arnaud; Dennis, Grant; Curry, Will; Matthews, Jason

Abstract

Over the last 20 years, finite element analysis (FEA) has become a standard analysis tool for metal joining processes. When FEA tools are combined with design of experiments (DOE) methodologies, academic research has shown the potential for virtual DOE to allow for the rapid analysis of manufacturing parameters and their influence on final formed products. However, within the domain of bulk-metal joining, FEA tools are rarely used in industrial applications and limit DOE trails to physical testing which are therefore constrained by financial costs and time. This research explores the suitability of an FEA-based DOE to predict the complex behaviour during bulk-metal joining processes through a case study on the staking of spherical bearings. For the two DOE outputs of pushout strength and post-stake torque, the FEA-based DOE error did not exceed ±1.2% and ± 1.5 Nm respectively which far surpasses what was previously capable from analytically derived closed-form solutions. The outcomes of this case study demonstration the potential for FEA-based DOE to provide an inexpensive, methodical, and scalable solution for modelling bulk-metal joining process

• Presentation Conference Type: Conference Paper (published)
• Conference Name: 24th International Conference on Engineering Design (ICED23)
• Start Date: Jul 24, 2023
• End Date: Jul 28, 2023
• Online Publication Date: Jun 19, 2023
• Publication Date: Jul 31, 2023
• Deposit Date: Aug 2, 2023
• Publicly Available Date: Aug 3, 2023
• Publisher: Cambridge University Press
• Volume: 3
• Pages: 1815-1824
• Series ISSN: 2732-527X
• Book Title: Proceedings of the Design Society
• DOI: https://doi.org/10.1017/pds.2023.182
• Public URL: https://uwe-repository.worktribe.com/output/11001549