ISSN:
0029-5981
Keywords:
finite element method
;
shape optimization
;
sensitivity analysis
;
forming process
;
optimal design
;
forging
;
Engineering
;
Engineering General
Source:
Wiley InterScience Backfile Collection 1832-2000
Topics:
Mathematics
,
Technology
Notes:
We suggest a shape optimization method for a non-linear and non-steady-state metal forming problem. It consists in optimizing the initial shape of the part as well as the shape of the preform tool during a two-step forging operation, for which the shape of the second operation is known. Shapes are described using spline functions and optimal parameter values of the splines are searched in order to produce, at the end of the forging sequence, a part with a prescribed geometric accuracy, optimal metallurgical properties and for a minimal production cost. The finite element method, including numerous remeshing operations, is used for the simulation of the process. We suggest using a least-squares-type algorithm for the unconstrained optimization method (based on external penalty) for which we describe the calculation of the derivatives of the objective function. We show that it can reduce to calculations which are equivalent to the derivative calculations of steady-state processes and to evolution equations. Therefore, the computational cost of such an optimization is quite reasonable, even for complex forging processes. Lastly, in order to reduce the errors due to the numerous remeshings during the simulation, we introduce error estimation and adaptive remeshing methods with respect to the calculation of derivatives.
Additional Material:
6 Ill.
Type of Medium:
Electronic Resource
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