Optimization of metal forming processes

Metal forging process design is formulated as an optimization problem. A thermal-mechanical finite element formulation, in conjunction with an elitist evolutionary search strategy is used to obtain optimal designs satisfying specific criteria. Geometric and process design variables of the tool and work-piece are considered in order to achieve the prescribed final forged product. An example demonstrating the efficiency of the developed method is presented considering a two-stage hot forging process. An inverse problem formulation is adopted in order to optimize the material design, minimize the process energy and simultaneously bounding the work-piece maximum temperature reached along the forging process.