Abstract
In this paper, a shape optimization technique is presented for the cold and hot isostatic pressing of metal powders based on the genetic algorithm (GA) approach. The GA technique is used to obtain the desired optimal compacted component by changing the boundaries of component and verifying the prescribed constraints. The coupled thermomechanical analysis of hot isostatic pressing is employed for metal powders during densification process. The numerical modeling of hot powder compaction simulation is performed based on the large deformation formulation, temperature-dependent cap plasticity model, and frictional contact algorithm. The modified cap plasticity takes the temperature effects into the numerical simulation of highly nonlinear behavior of metal powder. Finally, numerical examples are analyzed to demonstrate the feasibility of proposed optimization algorithm for designing powder components in the cold- and hot-forming processes of powder compaction.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Goldberg DE (1989) Genetic algorithms in search optimization and machine learning. Addison-Wesley, Reading
Khoei AR, Lewis RW (1998) Finite element simulation for dynamic large elasto-plastic deformation in metal powder forming. Finite Elem Anal Des 30:335–352
Haggblad HA, Oldenburg M (1994) Modeling and simulation of metal powder die pressing with use of explicit time integration. Model Simul Mater Sci Eng 2:893–911
Brandt J, Nilsson L (1999) A constitutive model for compaction of granular media with account for deformation induced anisotropy. Mech Coh Fric Mater 4:391–418
Keshavarz SH, Khoei AR, Khaloo AR (2008) Contact friction simulation in powder compaction process based on the penalty approach. Mater Des 29:1199–1211
Jinka AGK, Lewis RW (1994) Finite element simulation of hot isostatic pressing of metal powders. Comp Meth Appl Mech Eng 114:249–272
Svoboda A, Haggblad HA, Nasstrom M (1996) Simulation of hot isostatic pressing of metal powder components to near net shape. Eng Comput 13:13–37
Jinka AGK, Bellet M, Fourment L (1997) A new 3D finite element model for the simulation of powder forging processes: application to hot forming of PM connecting rod. Int J Numer Meth Eng 40:3955–3978
Khoei AR, Keshavarz Sh, Biabanaki SOR (2010) Optimal design of powder compaction processes via genetic algorithm technique. Finite Elem Anal Design 46:843–861
Zhao G, Wright E, Grandhi RV (1997) Preform die shape design in metal forming using an optimization method. Int J Numer Meth Eng 40:1213–1230
Antonio CAC, Dourado NM (2002) Metal forming process optimization by inverse evolutionary search. J Mater Proc Tech 121:403–413
Sousa LC, Castro CF, Antonio CAC, Santos AD (2002) Inverse methods applied to industrial forging processes. Int J Form Proc 4:463–479
Holland JH (1992) Adaptation in natural and artificial systems. University of Michigan Press, USA
Michalewicz Z (1992) Genetic algorithms + data structures = evolution programs. Springer, Berlin
Roy S, Ghosh S, Shivpuri R (1997) A new approach to optimal design of multi-stage metal forming processes with micro genetic algorithms. Int J Mach Tool Manufact 37:29–44
Castro CF, Sousa LC, Antonio CAC, César de Sá J (2001) An efficient algorithm to estimate optimal preform die shape parameters in forging. Eng Comput 18:1057–1077
Amirjanov A (2006) The development of a changing range genetic algorithm. Comp Meth Appl Mech Eng 195:2495–2508
Khoei AR, Biabanaki SOR, Vafa AR, Yadegaran I, Keshavarz SH (2009) A new computational algorithm for contact friction modeling of large plastic deformation in powder compaction processes. Int J Solids Struct 46:287–310
Ransing RS, Gethin DT, Khoei AR, Mosbah P, Lewis RW (2000) Powder compaction modelling via the discrete and finite element method. Mater Des 21:263–269
Martin CL, Bouvard D, Shima S (2003) Study of particle rearrangement during powder compaction by the discrete element method. J Mech Phys Solids 51:667–693
Khoei AR, Lewis RW (1999) Adaptive finite element remeshing in a large deformation analysis of metal powder forming. Int J Numer Meth Eng 45:801–820
Gasik M, Zhang B (2000) A constitutive model and FE simulation for the sintering process of powder compacts. Comput Mater Sci 18:93–101
Gu C, Kim M, Anand L (2001) Constitutive equations for metal powders: application to powder forming processes. Int J Plasticity 17:147–209
Lewis RW, Khoei AR (2001) A plasticity model for metal powder forming processes. Int J Plasticity 17:1659–1692
Chtourou H, Gakwaya A, Guillot M (2002) Modeling of the metal powder compaction process using the cap model. Part II: numerical implementation and practical applications. Int J Solids Struc 39:1077–1096
Khoei AR, DorMohammadi H, Azami AR (2007) A three-invariant cap plasticity model with kinematic hardening rule for powder materials. J Mater Proc Tech 187:680–684
Hrairi M, Chtourou H, Gakwaya A, Guillot M (2011) Modeling the powder compaction process using the finite element method and inverse optimization. Int J Adv Man Tech 56:631–647
Frost HJ, Ashby MF (1982) Deformation-mechanism maps: the plasticity and creep of metals and ceramics. Pergamon, Oxford
Doremus P, Geindreau C, Martin A, Debove L, Lecot R, Dao M (1995) High pressure triaxial cell for metal powder. Powder Metal 38:284–287
Khoei AR, Azizi S (2004) Numerical simulation of 3D powder compaction processes using cone-cap plasticity theory. Mater Des 26:137–147
Khoei AR (2002) Numerical simulation of powder compaction processes using an inelastic finite element analysis. Mater Des 23:523–529
Khoei AR, Azami AR, Anahid M, Lewis RW (2006) A three-invariant hardening plasticity for numerical simulation of powder forming processes via the arbitrary Lagrangian–Eulerian FE model. Int J Numer Meth Eng 66:843–877
Shen WM, Kimura T, Takita K, Hosono K (2001) Numerical simulation of powder transfer and compaction based on continuum model. In: Mori K (ed) Simulation of materials processing: theory, methods and applications. Swets & Zeitlinger, Lisse, pp 1027–1032
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Keshavarz, S., Khoei, A.R. & Molaeinia, Z. Genetic algorithm-based numerical optimization of powder compaction process with temperature-dependent cap plasticity model. Int J Adv Manuf Technol 64, 1057–1072 (2013). https://doi.org/10.1007/s00170-012-4053-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-012-4053-z