Optimum process design in sheet-metal forming with finite element analysis

Abstract

Process optimization is carried out to determine process parameters which satisfy the given design requirements and constraint conditions in sheet-metal forming processes. The scheme incorporates with a rigid-plastic finite element method for calculation of the final shape and the strain distribution. The optimization scheme adopts a direct differentiation method or a response surface methodology in order to seek for the optimum condition of process parameters. The algorithm developed is applied to design of the draw-bead force and the die shapes in deep drawing processes. Results show that design of process parameters is well performed to increase the amount of strain for increasing the strength or to decrease the amount of strain for preventing fracture by tearing. The present algorithm also enhances the stable optimum solution with small number of iterations for optimization.