Objective
Foreseen Results
Forging processes are non-linear and path-dependent and one of the most difficult tasks in optimizing them is the efficient evaluation of sensitivities, i.e. the derivatives of the objective function with respect to design parameters. In this project the direct differentiation and adjoint methods will be applied as a replacement for the commonly used but inefficient numerical approximations.
Practical assessment
A number of typical optimization problems related to metal forming technology will be formulated and solved to demonstrate the applicability of the approach. A manufacturer of flexible tooling systems is employed in this project to provide practical verification of our results which will help the consortium to promote the use of quantitative optimization techniques and flexible tooling systems in metal forming industry.
The main goal of the proposed project is to develop a computational tool for automatic optimization of multistage forging processes. The tool will automatically design the preform required to achieve the desired geometry and material state whilst maintaining a good service life for the tooling system.
Attention will be focused on two main problems. First, how to formulate an optimization problem which describes the intentions of a process designer in mathematical terms and secondly, how to solve the optimization problem in a computationally efficient way.
Formulation of the optimization problem
The formulations of the optimization problems will be generalized such that they will represent as closely as possible practical demands in the metal forming industry such as good die filling, low material and tool damage, desired microstructural changes and texture evolution, minimum surface wear and fatigue, etc. Although many of these phenomena which interact during forming operations are not fully understood to- date, several simplified models for quantifying them are available in the literature. These models will be systematically incorporated into the optimization system by means of an objective function and parameter constraints.
Solution technique
In order to solve the optimization problem our finite element system will be extended to evaluate the sensitivity of the forging process with respect to preform shape and to automatically update the preform using an iterative optimization procedure.
Fields of science (EuroSciVoc)
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
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Funding scheme (or “Type of Action”) inside a programme with common features. It specifies: the scope of what is funded; the reimbursement rate; specific evaluation criteria to qualify for funding; and the use of simplified forms of costs like lump sums.
Coordinator
SA2 8PP SWANSEA
United Kingdom
The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.