FEM-based process optimal design in steady-state metal forming considering strain-hardening

A process optimal design methodology applicable to steady-state forming with a strain-hardening material is presented. In this approach, the optimal design problem is formulated on the basis of a rigid-viscoplastic finite element process model, and a derivative based approach is adopted as an optimization technique. The process model, the formulation for process optimal design, and the schemes for the evaluation of the design sensitivity considering the effect of strain-hardening are described in detail. The validity of the proposed approach is demonstrated through numerical tests and application to die shape optimal design in extrusion.