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Abstract: The theory of grey systems is a new technique for performing prediction, relational analysis and decision making in many areas. In this paper, the use of grey relational analysis for optimizing the square hole flanging process parameters with considerations of the multiple response (the average flanging height, regular flanging and maximum strain) is introduced. Various flanging parameters, such as the blank inner radius r_b, blank inner width B₀, are considered. An orthogonal array is used for the experimental design. multiple response values are obtained using finite element analysis (FEA). Optimal process parameters are determined by the grey relational grade obtained from the grey relational analysis for multi-performance characteristics (flanging height, regular flanging and maximum strain). Analysis of variance (ANOVA) for the grey relational grade is implemented. The results showed good agreement with the experiment result. grey relational analysis can be applied in multiple response optimization designs.

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