Simulation and Knowledge Based Process Planning Through the Use of Metamodels

Planning a forming strategy to produce a complex geometry is still a challenge due to lack of intelligent software tools that support the designer. Finite element (FE) simulations can be used to predict material flow and feasibility of a metal forming process. In this work metamodels were used as a bridge to combine knowledge-based layout of forming steps and simulation-based process planning. This new approach makes it possible to suggest numerical validated process plans for a forming feature to the designer. The whole design space of possible process parameter variations was sampled regarding quality criteria (damage, topology deviations, maximum force) using computer experiments to get the support points of the metamodels. To handle this high workload of computer experiments an automated workflow was created based on scripts and FE tools. The fitted metamodels can be used to get hints regarding feasibility when no accurate numerical simulation results are yet available to the designer. Moreover the models can be used for fast optimization given the small computational cost of the function evaluation of metamodels. A computer aided process planning (CAPP) system was developed based on metamodels. The present concept is demonstrated for the forming feature "chimney extrusion".