Automatic Optimization Techniques Applied to a Large Range of Industrial Test Cases

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Automatic Optimization Techniques Applied to a Large

Range of Industrial Test Cases

Richard Ducloux, Lionel Fourment, Stéphane Marie, Dominique Monnereau

To cite this version:

Richard Ducloux, Lionel Fourment, Stéphane Marie, Dominique Monnereau. Automatic Optimization Techniques Applied to a Large Range of Industrial Test Cases. 13th ESAFORM Conference on Ma-terial Forming, Apr 2010, Brescia, Italy. pp.Pages 53-56, �10.1007/s12289-010-0705-4�. �hal-00851434�

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,E-2 C44CF72 CA2 E997CAD2 59C2C:EC5A2 7AC9F782 52 E2 52972 67EC72 EAB2 52 4562EC:72 E2 9E6CFE62 59C2EC72 6C76C5A26C2C82547A2E22C2=7677A2729FEC7254272 9E62 ,6C76CE2 =E87B2 5A2 7625327EACE2 C85672 EAB2 E<2542B74EF-2EAB2C82582,72E25FA25422E76CE2F87B2 B776C56EC5A2542558279FC927A2877C5A-022

,=-2 45297C72 542 6C972 5F9CAD2 =7677A2 72 5672 59C2C:EC5A2 8C2FEC5A2 8546E672 EAB2 9588C=72 42 8546E6702

,-2 C44CFC782 CA2 72 45622 542 5=;7C%72 4FAC5A82 E2 2E<72 BC44CF2 72 F872 542 4C68356B762 ED56C282 EAB2 72 C272 542 7%EFEC5A2 6C2 5FB2 7FB72 72 :765356B762 ED56C2802

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Figure 1: Overview of MAES.

4762 E%CAD2 6FA2 72 )0*02 8C2FEC5A82 4562 72 CACCE2 959FEC5A2 72λ2 =782 87CAD82 E672 8777B2 6752=CA7B2 EAB2 2FE7B2 52 7C7B2µ2 CB67A02 72 678F82 542 72 967%C5F872 97645627B2 )0*02 EFEC5A82 E672 F87B2 52 4C2 E2 B6CDCAD227E325B72852CA87EB25426FAACAD272797A8C%72 )0*02 EFEC5A82 4562 72µ2 CB67A2 72 678F82 E672 4C682 78C2E7B02 72 5=;7C%72 4FAC5A2 %EF782 12 E672 A52 BC6772E9965C2E7B2=72 112=F2=72 11−∆11267672∆112 C82 72 552 7EA2 9FE672 *66562 542 72 B6CDCAD2 E9965C2EC5A0 11−∆112 C82 72234567 189A65B902 5E87B2 5A2 7872 967BCC5A82 5A72 72 '&C2 =782 CABC%CBFE82 E672 EFE72 7%EFE7B2 =72 6FAACAD2 72 )0*02 8C2FEC5A802 8A2 C82 6E72 72 27E325B7CAD2 7AC9F72 8E%782 D&C2 542 C2735A8F2CAD2EFEC5A80272B6CDCAD227E325B72C82 7A2 F9BE7B2 EAB2 C82 9657BF672 C82 6797E7B2 FAC2 72 2EC2F22AF2=762542)0*028C2FEC5A82C8267E7B02 56BCAD25272965=7228C:727E2)0*02EFEC5A2EA2 =72 6FA2 5A2 E2 76ECA2 AF2=762 542 9657885682CDEFE2 82 C82

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=72 F87B2 4562 72 9E6E72 EFEC5A82 6C2 E2 %7672 CD2 744CC7A702 2

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72*2ED56C226E82873F926C2E2959FEC5A2542$(2 CABC%CBFE82 ,#2 9E67A82 EAB2 +"2 CB67A-02 2 7E2 D7A76EC5A2 5A72 #2 7E2 EFEC5A82 ,'&C-2 E672 E66C7B2 5F25A272E%ECE=72F8762542+'256782325A8C8CAD2542D2 A5B782542$3567296578856802)5627E2CABC%CBFE272652 456DCAD287982E672EFE7B2CA29E6E725A272$256782542 7E2 A5B72 6C72 72 #2 CABC%CBFE82 E672 EFE7B2 CA2 9E6E72 5A2 E22EC2F22 542(2 A5B782 CA2 652 =E78028A2 E2 4C682E9965E2722EC2F22AF2=762542D7A76EC5A826E82 87252"24562E25E2542($27E2456DCAD28C2FEC5A802 )CDF672'285682652967456228E9782E2E%72=77A2787B2 =72 72 ED56C202 772 E%72 8C2CE62 2E882 =F2 %7672 BC44767A2 E8972 6EC5802 8A2 )CDF672 $2 45F62 8C2FEC5A2 678F82E67296787A7B0272=5522742E8726796787A82EA2 FA4C7B2 5A4CDF6EC5A2 67672 72 5295A7A2 B7EC82 B52 A52 E997E602 72 =5522 6CD2 E872 E5682 9659762 4CCAD2 =F2 72 2E882 C82 9FC72 E6D702 8A2 89C72 542 C82 2E882 E2 C82 7E%C762 EA2 72 592 6CD2 85FC5A2 72 592 742 85FC5A2 B5782 A52 965%CB72 E2 9659762 4CCAD2 542 72 CA2 E6202 72 7%5FC5A2 542 =52 72 5A86ECA2 EAB2 5=;7C%72 4FAC5A82 E5AD2 6C2 72 D7A7C2 D7A76EC5A82 E672 957B2 CA2 )CDF672 (2 6C72 )CDF672 "2 25672 7E672 85682 72 67CD2 67BFC5A02 772 8562 72 5A%76D7A72 542 72 *2 ED56C22 56E6B2 E2 9FC72 8EC84E5672 85FC5A2 6CCA2 5A72"2D7A76EC5A8E2724CCAD25A86ECA2C828EC84C7B2E4762 72 4C682 D7A76EC5A2 542 72 ED56C22 EAB2 72 4556CAD2 D7A76EC5A82 E5682 2CAC2C:CAD2 72 96745622 2E882 46522 '"0.2<D252'(0F2<D02

2

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Figure 3: Closed-die forging of a “common rail” component – end of the second step of forging.

2

Figure 4: Final shape of the component for different results of optimization.

2

Figure 5: Pareto plot in the mass (horizontal axis) / die

filling (vertical axis) frame of the calculated solutions at the different generations of MAES.

2

Figure 6: Minimum weight of the individual of each

generation satisfying the filling constraint.

-

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476255CAD2E2E82=C727C=C825EC:7B295658CC782 E2 EA2 =72 EFE7B2 F8CAD2 E2 GE2EAE<E2 25B72 ,8772 )CDF672F-028A256B762525872787295658CC78272=C72C82 597A3BC72 456D7B2 CA2 56B762 52 D72 E2 89FE672 87C5A2 =72 .'2 87982 542 5DDCAD2 6C2 E2 #&H2 65EC5A2 =7677A2 7E02

)CDF672 D2 85682 72 67BFC5A2 542 7872 95658CC782 E2 BC44767A2 87982 542 5DDCAD02 72 59C2C:EC5A2 965=722 5A8C882 CA2 B7762CACAD2 72 4CAE2 7CD82 542 72 8F788C%72 865<782 AH.2 +2 (2 F2 #2 ,72 7CD2 542 865<72 AH'2C8279FE252725A72542865<72AH.2EAB28525A-26C2 965%CB72 (2 59C2C:EC5A2 9E6E277682 CA2 56B762 52 D72 E2 96786C=7B2 87C5A2 E4762 72 .'2 865<72 ,72 672ECACAD2 652 865<782 E%72 96786C=7B2 7CD8-2 EAB2 52 59C2C:72 722E76CE2B74562EC5A2456258CAD27295658CC7802

2

Figure 7: Isovalues of the Yamanaka porosity model at

the end of cooling of the initial billet.

2

2

2

2

Figure 8: Reduction of the 0.2 isovalue of porosity at

different phases of the cogging strokes.

EFEC5A82 67672 E66C7B2 5F2 CA2 9E6E72 ,CA2 652 =E78-2 E2 7E2 D7A76EC5A2 7E2 876C782 542 .'2 456DCAD2 87982 =7CAD2 EFE7B2 CA2 9E6E72 5A2 72 $2 56782 96578856802 72 2EC2F22 AF2=762 542 D7A76EC5A82 6E82 87252(24562E25E2542F(27E2456DCAD28C2FEC5A802 72678F82542C824C682=E2542EFEC5A82676729FC72 8EC84E5672 E82 EA2=72 877A2 CA2 )CDF672 #2 E2 85682 72 59C2E2 5=ECA7B2 85FC5A2 CA2 529E6C85A2 52 E2 7882 8EC84E567285FC5A02722E76CE295658CC782E%72=77A2 E25825E72587B27792E2726527AB8254272=E62 6767277267672CACCE72E6D762EAB267672729657882 744CC7A72C82567602 2 2

Figure 9: 0.2 isovalue of porosity at the end of cogging

for a good (top) and for the optimal (bottom) solutions.

74B72F64B8

9C2C:EC5A2 ED56C282 =E87B2 5A2 27E325B7CAD2 7AC9F782 EA2 =72 E99C7B2 52 EFE2 EAB2 %7672 52972 27E2 4562CAD2 965=72802 72 529FEC5AE2 C272 C82 672 EAB7B2 =72 72 9E6E7C:EC5A2542 72 7%5FC5AE672 ED56C22CA2EBBCC5A252729E6E7C:EC5A254272)0*02 8546E672 C87402 452972 B78CDA2 965=7282 EA2 =72 E<7B2C<727296787A7B2967456228E972B78CDA2456272 456DCAD2 542 E2 5225A2 6EC2 EAB2 72 EC7%727A2 542 EA2 E6EC%722E88267BFC5A2562C<72729657882B78CDA24562 725DDCAD2542E2=E626C2E2E6D72AF2=7625429E6E277682 EAB2725=ECACAD2542E28EC84E56722C65386FF6702 2

17(B4*CC5CB38

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