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In this paper, the blank shape is optimized by three approaches: a slow and accurate method, sensitivity analysis, a fast and approximate method, fuzzy logic decision-making, and finally, a novel quick and precise way was introduced by a combination of sensitivity analysis and fuzzy logic. It is shown that by using hybrid fuzzy logic-sensitivity, the number of iterations has been reduced down to 1 iteration in both cylindrical and square punch forming when the allowable geometrical error was considered to be less than the 1% of target size. The fuzzy logic code was written in Matlab software, and commercial finite element code Abaqus was used to simulate the forming process. Also, the results of the simulations obtained from finite element method analysis were verified experimentally on AL1050-O sheet for two different cylindrical and square die configurations. There was close agreement between the results of simulations and experiments. The difference was within the acceptable range of almost 3.5% in the square die and 1.8% in the cylindrical die.

Blank shape optimization in sheet metal processing using a hybrid fuzzy-sensitivity method