A Gradient Based Optimization Framework for the Design of Single and Multi-Stage Metal Forming Processes
Abstract A gradient based optimization methodology is developed for the design of metal forming processes. A novel, efficient and mathematically rigorous scheme is proposed for a continuum based sensitivity analysis of metal forming processes that can be used to accurately evaluate gradients of the objective function and design constraints. In particular, a sensitivity analysis is being developed for the Lagrangian analysis of finite inelastic deformations of hyperelastic-viscoplastic materials involving frictional contact. A framework for shape as well as parameter optimization for single-stage metal forming processes was introduced in [1–4]. Weak sensitivity equilibrium equations were derived for the large deformation of the workpiece in a typical forming operation. This sensitivity kinematic problem was linearly coupled with the appropriate sensitivity constitutive and contact sub-problems. Thus a linear sensitivity problem with appropriate driving forces was identified and the analysis carried out in an infinite dimensional framework. This work on the design of single-stage forming processes is currently expanded to include the design of multi-stage forming processes which necessarily involve the computation of both shape as well as non-shape (parameter) sensitivities. The direct deformation and sensitivity deformation problems are implemented using the finite element method. The effectiveness of the proposed methodology is tested here with the solution of two practical design problems in single and two-stage forming processing.