Metamodel-based optimization applied to crashworthiness and sheet metal hydroforming

A metamodel-based optimization approach is presented that can be used efficiently to replace complex, computationally expensive computer analysis and simulation codes in optimization. Kriging is used as the statistical interpolation technique. Optimization is performed using a gradient-free algorithm based on a Bayesian technique. The proposed approach is applied to problems of crashworthiness optimization and sheet metal hydroforming. The objective in the problem of crashworthiness optimization is to minimize the sum of maximum section force and maximum displacement in the rails of a bumper-rail assembly of an automobile. The objective in sheet metal hydroforming is to arrive at an optimal fluid pressure-punch stroke path that would reduce wrinkling failures and allow for greater draw depths before rupturing. The proposed approach is efficient in terms of computational time involved in optimization.