Automatic Optimization of Initial Blank Shape in Production of All Kinds of Rectangular Parts in Computer Aided Hydroforming Process

In this research, an innovative method has been applied to obtain the shape of initial sheet in the forming of different rectangular geometries. So that we can define rules that automatically determine the optimal shape of the initial sheet at different heights. Sensitivity analysis method was used for optimization, and Python software was used to link with Abaqus software. By examining the geometrical parameters and forming pressure, a flowchart was presented to determine the appropriate pressure. By examining the height changes in different geometries, it was found that the optimization reduces the maximum pressure and the maximum radius of the punch, which were obtained by 4 and 8%, respectively. It was found that the difference in the size of the longitudinal and transverse sides of the section has a direct effect on the changes in the node coordinates to plot the target curve and reduces the number of optimization steps. According to the results, it was shown that by automation and determining the pressure flowchart, the shape of the initial sheet can be determined without repeating the optimization stages and experimental tests. It also prevents material waste.