Abstract
In this work, we present a gradient optimization technique for optimizing deformation processes. The optimization is based on the continuum sensitivity method (CSM). CSM involves differentiation of the governing field equations of the direct problem (constitutive, contact and kinematic problems) with respect to the design variables and development of the weak forms for the corresponding continuum sensitivity equations. The present 3D developments involve a novel regularized approach to the contact sensitivity problem that addresses the non‐differentiability of the contact constraints. A relevant 3D die design problem is considered highlighting the features of the metal forming design simulator developed.
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