ON THE DEVELOPMENT OF A THREE-DIMENSIONAL DEFORMATION PROCESS DESIGN SIMULATOR

摘要

Although simulation of metal forming processes using modern computational tools has reached an advanced stage, a deformation process design simulator in this field is still lacking. In this work, we present a novel and mathematically rigorous tool called the continuum sensitivity method (CSM) to accurately compute sensitivities (changes in the design objectives as a result of infinitesimal perturbation to the design parameters) and use it in a gradient optimization framework for process optimization and control in three-dimensional metal forming applications. CSM involves differentiation of the governing field equations of the direct problem (constitutive, contact and kinematic problems) with respect to the design variables and development of the weak forms for the corresponding sensitivity equations. This work is an extension of our earlier work where the problems were restricted to 2D and axisymmetric cases. Extension to 3D involves a novel approach to the formulation of the contact sensitivity problem. A number of industrially relevant multi-stage design problems related to preform and die design for desired properties in the final product are being considered highlighting the features of the metal forming design simulator developed in-house. Preliminary results for optimum preform design problems to minimize barreling in open-die forgings are presented here.