Optimisation of Shape Parameters and Process Manufacturing for an Automotive Safety Part

In recent years, the weight and the cost of automotive vehicles have considerably increased due to the importance devoted to safety systems. It is therefore necessary to reduce the weight and the production cost of components by improving their shape and manufacturing process. This work deals with a numerical approach for optimizing the manufacturing process parameters of a safety belt anchor using a genetic algorithm (NSGA II). This type of component is typically manufactured in three stages: blanking, rounding of the edges by punching and finally, bending with a 90° angle. In this study, only the rounding and the bending will be treated. The numerical model is linked to the genetic algorithm in order to optimize the process parameters. This is implemented by using ABAQUS© script files developed in the Python programming language. The algorithm modifies the script files and restarts the FEM analysis automatically. Lemaitre’s damage model is introduced in the material behaviour laws and implemented in the...