Artificial neural network-based sequential approximate optimization of metal sheet architecture and forming process

This paper introduces a sequential approximate optimization method that combines the finite element method (FEM), dynamic differential evolution (DDE), and artificial neural network (ANN) surrogate models. The developed method is applied to address two optimization problems. The first involves metamaterial design optimization for metal sheet architecture with binary design variables. The second pertains to optimizing process parameters in multi-stage metal forming, where the discrete nature arises owing to changing tool geometries across stages. This process is highly nonlinear, accumulating contact, geometric, and material nonlinear effects discretely through forming stages. The efficacy of the proposed optimization method, utilizing ANN surrogate models, is compared with traditionally used polynomial response surface (PRS) surrogate models, primarily based on low-order polynomials. Efficient learning of ANN surrogate models is facilitated through the FEM and Python integration framework. Initial data for surrogate model training is collected via Latin hypercube sampling and FEM simulations. DDE is employed for sequential approximate optimization, optimizing ANN or PRS surrogate models to determine optimal design variables. PRS surrogate models encounter challenges in dealing with nonlinear changes in sequential approximate optimization concerning discrete characteristics such as binary design variables and discrete nonlinear behavior found in multi-stage metal forming processes. Owing to the discrete nature, PRS surrogate models require more data and iterations for optimal design variables. In contrast, ANN surrogate models adeptly predict nonlinear behavior through the activation function's characteristics. In the optimization problem of Metal Sheet Architecture for design target C, the ANN surrogate model required an average of 4.6 times fewer iterations to satisfy stopping criteria compared to the PRS surrogate model. Furthermore, in the optimization of multi-stage deep drawing processes, the ANN surrogate model required an average of 6.1 times fewer iterations to satisfy stopping criteria compared to the PRS surrogate model. As a result, the sequential global optimization method utilizing ANN surrogate models achieves optimal design variables with fewer iterations than PRS surrogate models. Further confirmation of the method's efficiency is provided by comparing Pearson correlation coefficients and locus plots.