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Sensitivity analysis and optimization algorithms for 3D forging process design

Abstract : This paper presents several approaches for preform shape optimization in 3D forging. The process simulation is carried out using the FORGE3(R) finite element software, and the optimization problem regards the shape of initial axisymmetrical preforms. Several objective functions are considered, like the forging energy, the forging force or a surface defect criterion. Both deterministic and stochastic optimization algorithms are tested for 3D applications. The deterministic approach uses the sensitivity analysis that provides the gradient of the objective function. It is obtained by the adjoint-state method and semi-analytical differentiation. The study of stochastic approaches aims at comparing genetic algorithms and evolution strategies. Numerical results show the feasibility of such approaches, i.e. the achieving of satisfactory solutions within a limited number of 3D simulations, less than fifty. For a more industrial problem, the forging of a gear, encouraging optimization results are obtained
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Submitted on : Tuesday, November 2, 2010 - 11:30:28 AM
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Tien Tho Do, Lionel Fourment, Mehdi Laroussi. Sensitivity analysis and optimization algorithms for 3D forging process design. Materials Processing and Design: Modeling, Simulation and Applications - NUMIFORM 2004 - Proceedings of the 8th International Conference on Numerical Methods in Industrial Forming Processes, Jun 2004, Colombus, United States. ISBN : 0-7354-0188-8 - p.2026-2031, ⟨10.1063/1.1766832⟩. ⟨hal-00531254⟩



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