Parameterized Finite Element Analysis With Optimization of a Superplastic Forming Process Using ANSYS®

This paper is an approach, from the optimization techniques, the point of view, provided by Ansys® for a superplastic deformation process of a commercial Al and Cu alloy called SUPRAL 100 (Aluminum 2004). In the present study, a finite element analysis, followed by application of some software optimization features were carried out to predict the deformation mode in various predetermined conditions and to optimize the forming process and enhance the product quality. In this regard, were established two input parameters(Sample_diameter and Displacement Y Component) and two output parameters(Equivalent Stress Maximum and Total Deformation Maximum) to study how the latter are influenced by the former and which the optimization design effort magnitude is. After the finite element analysis was carried out, all optimization methods available in Ansys®, Design Exploration module, were applied(Direct Optimization, Response Surface Optimization, and Six Sigma Analysis) and results were studied as a measure of parameters influence, using Ansys®, Parameters Correlation, module. This study should be regarded as consisting of two separate analyses, but that complement each other: a finite element analysis of superplastic deformation and an analysis of the opportunities to optimize the forming process, respectively.