Abstract
To date, in the sheet forming process design the data base decision system based on experience and experimental observation has been commonly employed. This paper propose for the first time an optimum process design system based on two numerical simulation schemes. One is forming simulation using the finite element method. The other is mathematical programing, such as the grid search and simplex methods. In this system, the objective function is formulated by design parameters, such as tool size, process stage, and material properties. Optimum search is performed under a constraint condition by employing the nonlinear programing and finite element methods. This system is applied to the two-stage press forming of a thermoplastic plate to achieve uniform thickness of the products. It was confirmed by comparison with experimental observations that the hybrid method which combines the grid search method and simplex method can determine the optimum condition accurately and efficiently.
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