Optimization of a pipe end upsetting process

A method is proposed for the optimization, by finite element analysis, of design variables of sheet metal forming processes. The method is useful when the non-controllable process parameters (e.g. the coefficient of friction or the material properties) can be modelled as random variables, introducing a degree of uncertainty into any process solution. The method is suited for problems with large FEM computational times and small process window. The problem is formulated as the minimization of a cost function, subject to a reliability constraint. The cost function is indirectly optimized through a “metamodel”, built by “Kriging” interpolation. The reliability, i.e. the failure probability, is assessed by a binary logistic regression analysis of the simulation results. The method is applied to the u-channel forming and springback problem presented in Numisheet 1993, modified by handling the blankholder force as a time-dependent variable.