Optimal design of powder compaction processes via genetic algorithm technique

In this paper, an optimal design is performed for powder die-pressing process based on the genetic algorithm approach. It includes the shape optimization of powder component, the optimal design of punch movements, and the friction optimization of powder–tool interface. The genetic algorithm is employed to perform an optimal design based on a fixed-length vector of design variables. The technique is used to obtain the desired optimal compacted component by verifying the prescribed constraints. The numerical modeling of powder compaction simulation is applied based on a large deformation formulation, powder plasticity behavior, and frictional contact algorithm. A Lagrangian finite element formulation is employed for large powder deformations. A cap plasticity model is used in numerical simulation of nonlinear powder behavior. The influence of powder–tool friction is simulated by a plasticity theory of friction to model sliding resistance at the powder–tool interface. Finally, numerical examples are analyzed to demonstrate the feasibility of the proposed optimization algorithm for designing powder components in the forming process of powder compaction.