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

DS 122: Proceedings of the Design Society: 24th International Conference on Engineering Design (ICED23)

Year: 2023
Editor: Kevin Otto, Boris Eisenbart, Claudia Eckert, Benoit Eynard, Dieter Krause, Josef Oehmen, Nad
Author: Hatherell, Jacob (1); Marmier, Arnaud (1); Dennis, Grant (2); Curry, Will (2); Matthews, Jason (1)
Series: ICED
Institution: 1: University of the West of England; 2: SKF (U.K) Ltd
Section: Design Methods
Page(s): 1815-1824
DOI number: https://doi.org/10.1017/pds.2023.182


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

Keywords: Simulation, Computational design methods, Case study, Optimisation

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