On the effect of numerical noise in approximate optimization of forming processes using numerical simulations

The coupling of Finite Element (FE) simulations with approximate optimization techniques is becoming increasingly popular in forming industry. By doing so, it is implicitly assumed that the optimization objective and possible constraints are smooth functions of the design variables and, in case of robust optimization, design and noise variables. However, non-linear FE simulations are known to introduce numerical noise caused by the discrete nature of the simulation algorithms, e.g. errors caused by re-meshing, time-step adjustments or contact algorithms. The subsequent usage of metamodels based on such noisy data reduces the prediction quality of the optimization routine and is known to even magnify the numerical errors. This work provides an approach to handle noisy numerical data in approximate optimization of forming processes, covering several fundamental research questions in dealing with numerical noise. First, the deteriorating effect of numerical noise on the prediction quality of several well-known metamodeling techniques is demonstrated using an analytical test function. Next, numerical noise is quantified and its effect is minimized by the application of local approximation and regularization techniques. A general approximate optimization strategy is subsequently presented and coupling with a sequential update algorithm is proposed. The strategy is demonstrated by the sequential deterministic and robust optimization of 2 industrial metal forming processes i.e. a V-bending application and a cup-stretching application. Although numerical noise is often neglected in practice, both applications in this work show that the general awareness of its presence is highly important to increase the overall accuracy of optimization results.