Optimization of a range of 2D and 3D bulk forming processes by a meta-model assisted evolution strategy

After decades of developing efficient software, FORGE, for bulk metal forming simulation, its coupling with an optimization algorithm is considered in order to solve the actual engineering problem, the design problem, using the meta-model assisted evolution strategy proposed by Emmerich et al. The first application regards the shape optimization of a cylindrical preform to produce a crankshaft by closed die forging. It aims at minimizing the volume of the material while satisfying the filling of the dies. In the second application, the open die forging of an axisymmetric thick plate is considered. The objective is to optimize the initial geometry in order to minimize the material weight while overlapping a prescribed geometry at the end of forging. The third example regards a four-stepped wire drawing sequence. In order to prevent the formation of cracks, it is desired to minimize a damage criterion while keeping the targeted diameter of the final wire. The geometries of the four dies are optimized: reduction ratio, die angle and die length. The necessary calculations are run in parallel, by using both the parallel version of the software and by evaluating several designs at the same time.