Continuum sensitivity method for the design of multi-stage metal forming processes

As part of this continuing DMI-funded NSF project, a novel, efficient and mathematically rigorous continuum based sensitivity method is being developed that can be used to accurately evaluate the gradients of the objective function and constraints in the design optimization of multi-stage deformation processes. The sensitivity methods developed allow for a unified treatment of both shape and parameter sensitivity analysis that are present in a typical design problem of multi-stage deformation processes. The continuum sensitivity method was recently extended to thermoplasticity combined with ductile damage at finite strains. The computed sensitivity fields are used within the developed gradient-based optimization framework for the computational design of metal forming processes for porous materials. The effectiveness of the proposed methodology is demonstrated with the solution of practical problems in the design of one-stage and two-stage metal forming processes.