A new approach to optimal design of multi-stage metal forming processes with micro genetic algorithms

This paper describes a new method for design optimization of process variables in multi-stage metal forming processes. The selected forming processes are multi-pass cold wire drawing, multi-pass cold drawing of a tubular profile and cold forging of an automotive outer race preform. An adaptive micro genetic algorithm (mu GA) scheme has been implemented for minimizing a wide variety of objective-cost functions relevant to the respective processes. The chosen design variables are die geometry, area reduction ratios and the total number of forming stages. Significant improvements in the simulated product quality and reduction in the number of passes has been observed as a result of the micro genetic algorithms-based optimization process. Copyright (C) 1996.