Optimisation methods for initial/tool shape optimisation in metal forming processes

Nowadays, the computer simulations of metal forming processes using the finite element method (FEM), have reached some level of maturity. Inverse problems purpose is to determine one or more of these forming processes simulations input data, leading to a desired result. A first example that has now become classical is called parameter identification. It consists in evaluating the material parameters for material behaviour laws that would lead to the most accurate model, minimising the difference between experimental and numerical results. Another example, which is much less extensively described in the literature is the initial geometry and tool shape design, which consists in determining the initial shape of the specimen and/or the shape of the forming tools, in order to provide the desired final geometry after forming process. In this paper, we will show how some optimisation methods are able to solve this shape optimisation problems. We will also compare the efficiency of the proposed numerical methods.