Abstract: The forming process of car dashboard shells based on outside mold three-dimensional filming technology was simulated so as to make the film thickness distribution more uniform and improve the accuracy of deformation. The process parameters were designed and analyzed by a central composite design method on the basis of the design of experiments analysis and the establishment of Kriging model, and then they are optimized by a multi-objective optimization method combined with the global particle swarm optimization and the gradient sequential quadratic programming optimization. The optimization results were further analyzed by an average reliability method in terms of 6-sigma reliability. The results indicated that, after such optimization, the reduction ratio increased by 3.21 %, the maximum deformation in the x-direction decreased by 25.63 %, and the maximum deformation in the y-high reliability.

Key words: outside mold three-dimensional filming technology, simulation, global optimization, gradient optimization, reliability