Advanced Methods in Material Forming

pp 55-72

A Metamodel Based Optimisation Algorithm for Metal Forming Processes

  • M.H.A. BonteAffiliated withUniversity of Twente, Faculty of Engineering Technology
  • , A.H. van den BoogaardAffiliated withUniversity of Twente, Faculty of Engineering Technology
  • , J. HuétinkAffiliated withUniversity of Twente, Faculty of Engineering Technology

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Cost saving and product improvement have always been important goals in the metal forming industry. To achieve these goals, metal forming processes need to be optimised. During the last decades, simulation software based on the Finite Element Method (FEM) has significantly contributed to designing feasible processes more easily. More recently, the possibility of coupling FEM to mathematical optimisation algorithms is offering a very promising opportunity to design optimal metal forming processes instead of only feasible ones. However, which optimisation algorithm to use is still not clear.

In this paper, an optimisation algorithm based on metamodelling techniques is proposed for optimising metal forming processes. The algorithm incorporates nonlinear FEM simulations which can be very time consuming to execute. As an illustration of its capabilities, the proposed algorithm is applied to optimise the internal pressure and axial feeding load paths of a hydroforming process. The product formed by the optimised process outperforms products produced by other, arbitrarily selected load paths. These results indicate the high potential of the proposed algorithm for optimising metal forming processes using time consuming FEM simulations.

Key words

optimisation metal forming finite element method meta-modelling hydroforming