Intuitionistic fuzzy TOPSIS-based optimization of microcups production from directionally rolled copper strips for sustainability

Simulation-assisted process development in metal forming is a valuable approach to bolstering sustainability by exploring alterations that can diminish the necessity for new metal production, thereby contributing to environmental preservation. Real-world industrial challenges often revolve around the quest for cost-effective and efficient manufacturing methods that uphold product quality, a fundamental requirement for maintaining competitiveness in the market. In this context, the study leverages the Intuitionistic Fuzzy Technique for Order Preference by Similarity to an Ideal Solution (Intuitionistic Fuzzy TOPSIS) approach, well-suited for situations characterized by continuous solution spaces and the high costs associated with experimental trials. Moreover, many industries grapple with the need to simultaneously optimize multiple response variables while striving to reduce operational costs and elevate product quality. The study’s control parameters are the maximum thinning rate (%), the forming limit curve (%), the resultant tool force (N), and the springback (µm). These parameters are crucial for monitoring the process and ensuring the quality of the results. The methodology employed Finite Element Analysis (FEA) to formulate an intricate eight-stage micro-deep drawing process tailored for fabricating micro-cups. We orchestrated the transformation of a copper strip, involving substantial rolling with a 250% deformation, a 2.78 strain rate, and a reduction in initial and final thickness from 6 to 0.18 mm. Each successive pass imposed a 6% strain. This comprehensive investigation delved into comprehending the intricate interplay between grain size and material deformation, underpinning the quest for high-quality microparts. The Intuitionistic Fuzzy TOPSIS approach was judiciously adopted to ascertain the optimality of process parameters for producing top-tier micro-cups. We meticulously executed explicit finite element simulations rooted in empirical material test data to replicate real-world manufacturing conditions. Subsequent real-time trials rigorously validated the optimized parameters and microstructural characteristics within the high-stress zone. This validation ensured superior product quality and structural integrity in the manufactured microcups.