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It’s crucial for process engineers to determine optimal value and combination of process parameters in the design of sheet metal forming. The multi-objective genetic algorithm (MOGA) based on Pareto approach and numerical simulation codes were integrated in this paper to fulfill the optimal formability in the sheet metal forming. Three objective functions of local formability on fracture, wrinkling and insufficient stretching were presented based on the strains state at the end of the forming process on the Forming Limit Diagram. By using Pareto-based MOGA, the optimal global formability which represents the trade-off between different local formability was decided. For the efficiency and accuracy of optimization procedure, both inverse and incremental finite element analysis were used to evaluate the value of objective functions. This method was applied to a complex engineering optimization problem: an engine hood outer panel, the optimal blank holder force and draw bead restraining forces were determined to satisfy the given objective functions for the forming of the auto body panels. The approach proposed in this paper has been shown to be a powerful tool than manual numerical simulation procedure. © 2005 American Institute of Physics [ABSTRACT FROM AUTHOR]

This paper presents an approach of combined direct compensation and surface approximation implemented in a forging optimization system in order to achieve net-shape forging for aeroengine blade components. This approach is based on modification of individual nodal positions on the die surface and approximation of the modified die surface using a B-spline surface for improved surface quality. The results show that, with this method, forging optimization computations not only produce fast converged solution in forging simulation but also provide significant reduction of the total forging error. © 2007 American Institute of Physics [ABSTRACT FROM AUTHOR]

Treatment of contact between a sheet and tools is one of the most difficult problems to deal with in finite-element simulations of sheet forming processes. In order to obtain more accurate tool models without increasing the number of elements, this paper describes a new formulation for contact problems using interpolation proposed by Nagata for tool surfaces. A contact search algorithm between sheet nodes and the interpolated tool surfaces was developed and was introduced into the static-explicit elastoplastic finite-element method code STAMP3D. Simulations of a square cup deep drawing process with a very coarsely discretized punch model were carried out. The simulated results showed that the proposed algorithm gave the proper drawn shape, demonstrating the validity of the proposed algorithm. © 2005 American Institute of Physics [ABSTRACT FROM AUTHOR]

Over the past two decades, various finite element formulations and solution techniques for metal forming analysis have been developed. Most finite element codes for bulk metal forming used in the industry today are based on static implicit solution schemes wherein a non-linear system of equations is solved iteratively for each time increment. For simple 2D problems, static implicit analysis models are generally known to be more accurate and efficient than dynamic explicit analysis models. However, for complex 3D forming problems, the static implicit procedures encounter a number of inherent difficulties especially in incremental forming processes such as ring rolling in which several surface nodes repeatedly make contact with and separate from the dies. Static implicit finite element formulations require a very long computational time for the analysis of ring rolling. Several solution techniques have been developed to reduce the computational time of static implicit finite element analysis, namely the dual mesh technique, Arbitrary Lagrangian Eulerian (ALE) technique, etc. The dynamic explicit method on the other hand appears to be very effective in analyzing complex incremental forming problems. In this paper, a comparison of the analysis results obtained using dynamic explicit finite element method and static implicit method using a dual mesh approach is presented. © 2004 American Institute of Physics [ABSTRACT FROM AUTHOR]