A metamodel based optimisation algorithm for metal forming processes

Cost saving and product improvement have always been important goals in the metal\ud forming industry. To achieve these goals, metal forming processes need to be optimised. During\ud the last decades, simulation software based on the Finite Element Method (FEM) has significantly\ud contributed to designing feasible processes more easily. More recently, the possibility of\ud coupling FEM to mathematical optimisation algorithms is offering a very promising opportunity\ud to design optimal metal forming processes instead of only feasible ones. However, which\ud optimisation algorithm to use is still not clear.\ud In this paper, an optimisation algorithm based on metamodelling techniques is proposed\ud for optimising metal forming processes. The algorithm incorporates nonlinear FEM simulations\ud which can be very time consuming to execute. As an illustration of its capabilities, the\ud proposed algorithm is applied to optimise the internal pressure and axial feeding load paths\ud of a hydroforming process. The product formed by the optimised process outperforms products\ud produced by other, arbitrarily selected load paths. These results indicate the high potential of\ud the proposed algorithm for optimising metal forming processes using time consuming FEM\ud simulations

Solving optimisation problems in metal forming using Finite Element simulation and metamodelling techniques

During the last decades, Finite Element (FEM) simulations\ud of metal forming processes have become important\ud tools for designing feasible production processes. In more\ud recent years, several authors recognised the potential of\ud coupling FEM simulations to mathematical optimisation\ud algorithms to design optimal metal forming processes instead\ud of only feasible ones.\ud Within the current project, an optimisation strategy is being\ud developed, which is capable of optimising metal forming\ud processes in general using time consuming nonlinear\ud FEM simulations. The expression “optimisation strategy”\ud is used to emphasise that the focus is not solely on solving\ud optimisation problems by an optimisation algorithm, but\ud the way these optimisation problems in metal forming are\ud modelled is also investigated. This modelling comprises\ud the quantification of objective functions and constraints\ud and the selection of design variables.\ud This paper, however, is concerned with the choice for\ud and the implementation of an optimisation algorithm for\ud solving optimisation problems in metal forming. Several\ud groups of optimisation algorithms can be encountered in\ud metal forming literature: classical iterative, genetic and\ud approximate optimisation algorithms are already applied\ud in the field. We propose a metamodel based optimisation\ud algorithm belonging to the latter group, since approximate\ud algorithms are relatively efficient in case of time consuming\ud function evaluations such as the nonlinear FEM calculations\ud we are considering. Additionally, approximate optimisation\ud algorithms strive for a global optimum and do\ud not need sensitivities, which are quite difficult to obtain\ud for FEM simulations. A final advantage of approximate\ud optimisation algorithms is the process knowledge, which\ud can be gained by visualising metamodels.\ud In this paper, we propose a sequential approximate optimisation\ud algorithm, which incorporates both Response\ud Surface Methodology (RSM) and Design and Analysis\ud of Computer Experiments (DACE) metamodelling techniques.\ud RSM is based on fitting lower order polynomials\ud by least squares regression, whereas DACE uses Kriging\ud interpolation functions as metamodels. Most authors in\ud the field of metal forming use RSM, although this metamodelling\ud technique was originally developed for physical\ud experiments that are known to have a stochastic na-\ud ¤Faculty of Engineering Technology (Applied Mechanics group),\ud University of Twente, P.O. Box 217, 7500 AE, Enschede, The Netherlands,\ud email: [email protected]\ud ture due to measurement noise present. This measurement\ud noise is absent in case of deterministic computer experiments\ud such as FEM simulations. Hence, an interpolation\ud model fitted by DACE is thought to be more applicable in\ud combination with metal forming simulations. Nevertheless,\ud the proposed algorithm utilises both RSM and DACE\ud metamodelling techniques.\ud As a Design Of Experiments (DOE) strategy, a combination\ud of a maximin spacefilling Latin Hypercubes Design\ud and a full factorial design was implemented, which takes\ud into account explicit constraints. Additionally, the algorithm\ud incorporates cross validation as a metamodel validation\ud technique and uses a Sequential Quadratic Programming\ud algorithm for metamodel optimisation. To overcome\ud the problem of ending up in a local optimum, the\ud SQP algorithm is initialised from every DOE point, which\ud is very time efficient since evaluating the metamodels can\ud be done within a fraction of a second. The proposed algorithm\ud allows for sequential improvement of the metamodels\ud to obtain a more accurate optimum.\ud As an example case, the optimisation algorithm was applied\ud to obtain the optimised internal pressure and axial\ud feeding load paths to minimise wall thickness variations\ud in a simple hydroformed product. The results are satisfactory,\ud which shows the good applicability of metamodelling\ud techniques to optimise metal forming processes using\ud time consuming FEM simulations

A Study For Efficiently Solving Optimisation Problems With An Increasing Number Of Design Variables

Coupling optimisation algorithms to Finite Element Methods (FEM) is a very promising way to achieve optimal metal forming processes. However, many optimisation algorithms exist and it is not clear which of these algorithms to use. This paper investigates the sensitivity of a Sequential Approximate Optimisation algorithm (SAO) proposed in [1-4] to an increasing number of design variables and compares it with two other algorithms: an Evolutionary Strategy (ES) and an Evolutionary version of the SAO (ESAO). In addition, it observes the influence of different Designs Of Experiments used with the SAO. It is concluded that the SAO is very capable and efficient and its combination with an ES is not beneficial. Moreover, the use of SAO with Fractional Factorial Design is the most efficient method, rather than Full Factorial Design as proposed in [1-4]

Surrogate modeling of the effective elastic properties of spherical particle-reinforced composite materials

This paper focuses on the development of a surrogate model to predict the macroscopic elastic properties of polymer composites doped with spherical particles. To this aim, a polynomial chaos expansion based Kriging metamodeling technique has been developed. The training experimental design is constructed through a dataset of numerical representative volume elements (RVEs) considering randomly dispersed spherical particles. The RVEs are discretized using finite elements, and the effective elastic properties are obtained by implementing periodic boundary conditions. Parametric analyses are reported to assess the convergence of the scale of the RVE and the mesh density. The accuracy of the proposed metamodelling approach to bypass the computationally expensive numerical homogenization has been evaluated through different metrics. Overall, the presented results evidence the efficiency of the proposed surrogate modelling, enabling the implementation of computationally intensive techniques such as material optimization.Spanish Government PID2020-116809GB-I00Junta de Extremadura (Spain) GR1802

Solving optimisation problems in metal forming using FEM: A metamodel based optimisation algorithm

During the last decades, Finite Element (FEM) simulations of metal forming processes have\ud become important tools for designing feasible production processes. In more recent years,\ud several authors recognised the potential of coupling FEM simulations to mathematical opti-\ud misation algorithms to design optimal metal forming processes instead of only feasible ones.\ud This report describes the selection, development and implementation of an optimisa-\ud tion algorithm for solving optimisation problems for metal forming processes using time\ud consuming FEM simulations. A Sequential Approximate Optimisation algorithm is pro-\ud posed, which incorporates metamodelling techniques and sequential improvement strate-\ud gies for enhancing the e±ciency of the algorithm. The algorithm has been implemented in\ud MATLABr and can be used in combination with any Finite Element code for simulating\ud metal forming processes.\ud The good applicability of the proposed optimisation algorithm within the ¯eld of metal\ud forming has been demonstrated by applying it to optimise the internal pressure and ax-\ud ial feeding load paths for manufacturing a simple hydroformed product. Resulting was\ud a constantly distributed wall thickness throughout the ¯nal product. Subsequently, the\ud algorithm was compared to other optimisation algorithms for optimising metal forming\ud by applying it to two more complicated forging examples. In both cases, the geometry of\ud the preform was optimised. For one forging application, the algorithm managed to solve\ud a folding defect. For the other application both the folding susceptibility and the energy\ud consumption required for forging the part were reduced by 10% w.r.t. the forging process\ud proposed by the forging company. The algorithm proposed in this report yielded better\ud results than the optimisation algorithms it was compared to

Surrogate modeling of RF circuit blocks

Surrogate models are a cost-effective replacement for expensive computer simulations in design space exploration. Literature has already demonstrated the feasibility of accurate surrogate models for single radio frequency (RF) and microwave devices. Within the European Marie Curie project O-MOORE-NICE! (Operational Model Order Reduction for Nanoscale IC Electronics) we aim to investigate the feasibility of the surrogate modeling approach for entire RF circuit blocks. This paper presents an overview about the surrogate model type selection problem for low noise amplifier modeling