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Utilisation of fuzzy logic and genetic algorithm to seek optimal corrugated die
design for CGP of AZ31 magnesium alloy
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3 authors:
Nageswara Rao
Koneru Lakshmaiah Education Foundation
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All content following this page was uploaded by Muni Tanuja Anantha on 09 April 2023.
To cite this article: Muni Tanuja Anantha, Tanya Buddi & Nageswara Rao Boggarapu (2023):
Utilisation of fuzzy logic and genetic algorithm to seek optimal corrugated die design for
CGP of AZ31 magnesium alloy, Advances in Materials and Processing Technologies, DOI:
10.1080/2374068X.2023.2192135
1. Introduction
Demand of lightweight materials for the technology advancement of electric vehicles,
drones and aerospace structures is increasing day-by-day due to cost effectiveness in
power consumption and fuel economy [1]. Magnesium alloys attracted significantly
among low-density metals family owing to abundant availability, high specific strength
and high strength to weight ratio. Good amount of research carried out to improve the
mechanical properties. Due to hexagonal closed packed (HCP) crystal structure, magne
sium alloys exhibited poor formability and low active slip system constraining to
structural applications [2,3]. Constrained groove pressing (CGP), friction stir processing
(FSP) and accumulative roll bonding (ARB) are being introduced to improve ductility
and formability. These severe plastic deformation (SPD) processes provide ultra-fine
grain structure that improves formability of metals. Plastic deformation processes
employed for modification in structure at local or bulk level [4]. CGP process utilised
for structural bulk deformation [5,6]. This process includes an alternative pressing under
a set of corrugated dies followed by straight dies and rotated with 180° between them that
takes place in number of cumulative passes in a plane strain pure shear conditions [7].
According to hall-pitch relationship, this process results in uniformly distributed grain
size and improves ductility in metals. Simple tool design in CGP process can be
implemented in bulk deformation of large volumes [8,9]. Few investigations made on
the plastic deformation under CGP process at room temperature due to poor formability
of magnesium alloys [10].
90% thickness shrinkage, improved ductility and fracture toughness. Sunil et al. [13]
initially used CGP to produce tiny grain size in AZ31 Mg alloy and examined the
surface characteristics, microstructure evolution on materials’ wettability, corrosion
resistance, in-vitro bioactivity, and cell adhesion. Fong et al. [14] examined the effects
of deformation path and temperature on microstructure, texture and mechanical
properties of AZ31B-O Mg alloy sheets developing an orthogonal CGP procedure
(involving four groove pressings, a 90° rotation of the sheet sample around its ND
after each pressing and a final flattening). Liu et al. [15] treated a highly deformed
material below recrystallisation temperature, which regains ductility and toughness
with considerable impact from precipitates within the matrix. As a result, straining
strengthens the ideal environment for further precipitation.
To achieve the refined grain structure, CGP process implemented in the body centred
cubic (BCC) and face Centered Cubic (FCC) crystal structured metals (such as aluminium,
copper base alloys, low carbon steels and nickel alloys). Thangapandian et al. [16] utilised
corrugated dies (V-groove, flat groove, and semi-circular) in repeating corrugation and
straightening (RCS) process, which improved the mechanical properties (tensile strength
and hardness) and uniform grain refinement with pass number. Moradpour et al. [17] used
CGP-cross route technique on Al – Mg alloy sheet to create fine grain structures with
increased strength. The number of passes relates directly to the degree of grain fineness.
Thuy et al. [2] utilised equivalent strain and strain inhomogeneity factor to define the
objective function. Hybrid GA implemented to find the optimal process parameters. 1st
pass of CGP on AZ 31 magnesium alloy with a new die geometry (die angle = 40°, groove
width = 2 mm and radius of corner = 0.3 mm) improved the yield strength by 85%.
Reham Reda et al. [23] worked on 1050 and 5052 aluminium alloys subjecting to 3
passes of CGP with intermediate annealing. For Al 1050, UTS, YS and the ratio of YS to
UTS increased with number of passes, whereas reduction in elongation. For Al 5052, UTS
and YS increased after 1st pass, decreased and increased after 2nd and 3rd passes.
These studies indicate the suitability of CGP method for achieving improved mechan
ical properties of AZ31 Mg alloy with optimal die. There is a need for optimising the die
design for fabrication and using it in the CGP process to understand the deformation
characteristics of the processed AZ31 Mg alloy sheet.
2. Die design
Two sets of dies are needed in the CGP process. One set of die serves for the corrugating
press, while the other set of die for the flattening press. Figure 2 illustrates the overview of
the corrugated die profile. Three parameters of die geometry under consideration (Groove
angle, Groove width and Coefficient of friction) with three levels are shown in Table 1.
The possible combination of die geometry as per the Taguchi’s design of experiments by
L9 OA (orthogonal array) is shown in Table 2. The die design is initiated with free sketch by
considering the dimension of the blank as 130 � 100 � 35 mm. The groove angle varies
from 40° to 50° and the groove width varies from 3 to 5 mm. Initially the number of
grooves within 130 mm blank length is determined. Each set of dies is modelled and
assembled as represented in Figure 3 using SolidWorks 2020 as per the L9 OA of Table 2.
The material opted for die is H13 steel (having splendid combination of toughness, heat
Figure 3. Die design in SolidWorks as per the combination of die geometry parameters in Table 2.
6 M. T. ANANTHA ET AL.
Table 3. Mechanical properties and chemical composition of the die material H13 steel.
C Mn P S Si Cr Mo V Fe
Chemical Composition (wt %)
0.3889 0.3616 0.0132 0.0045 0.8921 5.3792 0.3616 0.0132 Balance
Tensile Strength Yield strength Hardness Modulus of Elasticity (GPa) Poisson’s ratio
(MPa) (MPa) (HV)
Mechanical Properties
1434 1356 242, 240, 239 44.85 0.35
and fatigue resistance) and widely used in hot and cold working. The material composition
of H13 steel and the properties associated with it are shown in Table 3.
3. Numerical simulations
Finite element method (FEM) adopted for strain distribution in the CGP process.
Elasto-plastic analysis performed to examine the plastic deformation and strain
localisation characteristics of the process after one complete pass [24]. ANSYS
software package was used to simulate the plastic deformation behaviour of speci
mens after single groove pressing. Two-dimensional (2D) plane strain model is
appropriate for the expected minimal deformation in normal direction. CPE4 ele
ments employed for modelling and performed simulations for the 2D planar strain
conditions. The work piece dies interface’s coefficient of friction was set at 0.1,
which is within the normal (0.05–0.1) range for cold forming metals. On shing with
4-node isoparametric 2D plane strain element, the optimised model consists of 5496
elements with 26,052 nodes. Dimensions of the specimen specified are: 3 mm
thickness and 80 mm length (width is unity along the plane normal direction in
plane-strain condition). Analytical rigid lines were used to model the dies, while
CPE4 mesh was used to model the specimen. ANSYS simulations performed for all
the combinations of die geometry in Table 2. AZ31 Mg alloy sheets (Table 4 shows
the chemical composition and properties) are used to undergo deformation as per
the combination of parameters in L9 OA of Table 2.
ANSYS – Static structural simulations performed to examine the elasto-plastic
behaviour and changes in mechanical properties of AZ31 sheets during CGP process.
To attain the optimum design, the steps employed are: Defined the 3-D geometry
(length � width � height) of the die (130 � 100 � 35 mm) and AZ31 Mg alloy sheet
(110 � 90 � 3 mm); Attached the geometry (created in SolidWorks 2020) to the work
bench for performing simulations; Specified the material properties of H13 steel for the
die, whereas the properties of AZ31 Mg alloy for the sheet; CPE4 triangular elements
are selected for modelling, a Four-noded plane strain element. These elements are most
suitable for analysing thin to moderately thick shell structures. Regarding the boundary
conditions, the bottom die is fixed and 40 tons distributed load applied on the upper die
surface at a constant strain rate of 1 mm/s at room temperature. Numerical simulations
performed by clicking on the analysis type ‘structural analysis’. Simulation results of
total deformation, elastic strain and equivalent stress on AZ31 Mg alloy sheet are
summarised in Table 5.
ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES 7
Figure 8. Mamdani based fuzzy logic input and output membership relationship for grooved die
design.
Table 7. Rule editor established between input and output membership functions.
Coeff. of
Groove angle Groove width friction Total deformation Elastic strain Equivalent stress (MPa)
IF L & L & L THEN VL L L
IF L & M & M THEN M VL VL
IF L & H & H THEN H VL VL
IF M & L & M THEN L L VH
IF M & M & H THEN H M M
IF M & H & L THEN H L L
IF H & L & H THEN L M M
IF H & M & L THEN H VH VH
IF H & H & M THEN H M M
VL: VERY LOW; L: LOW; M: MEDIUM; H: HIGH; VH: VERY HIGH
12 M. T. ANANTHA ET AL.
Figure 9. Fuzzy prediction on total deformation and elastic strain for the specified groove width and
groove angle.
Figure 10. An error chart depicting the deviation of numerical simulations and fuzzy model
predictions.
ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES 13
6. Conclusions
In order to trace the optimal grooved die geometrical parameters, numerical simula
tions were carried out by adopting a simple and reliable hybrid optimisation techni
que to enhance the grain refinement in AZ31 Mg alloy through CGP (constrained
groove pressing) process. The observations drawn from the present investigations are
as follows:
● The plastic deformation behaviour of the material has been studied by ANSYS
simulations.
● A fuzzy predictive model was implemented to model an overall groove pressing
operation for a set of input parameters. The aim is to observe the deformation
behaviour of AZ31 magnesium alloy after pressing with a set of optimised grooved
die geometry. The results obtained show a permissible error of 7.86% when com
pared with simulation results.
● A multi-objective GA optimisation technique is employed to obtain the optimal die
design parameters as 50° groove angle, 3 mm groove width and 0.22 friction
coefficient with the motive of achieving minimum total deformation, high equiva
lent stress and elastic strain.
Disclosure statement
No potential conflict of interest was reported by the authors.
ORCID
Muni Tanuja Anantha http://orcid.org/0000-0001-5808-7661
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