Mathematical Optimization for the Virtual Design of Process Chains with Electromagnetic Forming
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Date
2016-04-27
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Abstract
In this work, a framework for virtual process design for coupled processes including
electromagnetic impulse forming is presented. Virtual process design is here understood as
the computer based identification of suitable geometry and process parameters to reach a
predefined forming result via physically feasible process paths. Implementation of this
concept relies on three pillars: a physical process model, its implementation within a
numerical simulation, and a mathematical optimization algorithm. This methodology is
particularly applied to a combination of deep drawing and subsequent electromagnetic
forming (EMF). In this case, the model is given by an anisotropic elasto-viscoplastic
material model augmented by damage evolution and coupled with the magneto-quasistatic
approximation to Maxwell's equations. For constrained mathematical optimization, an inner
point algorithm is applied. With this method for virtual process design at hand, several
technological problems are addressed including tool coil design and the identification of
ideal electrical parameters of the tool coil circuit. Employing this framework requires the
identification of the material model described above. It turns out that a high precision
identification of material parameters can be achieved with basically the same mathematical
algorithm as derived for process identification.
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Keywords
metal forming, finite element method, design optimization