Computational design of deformation processes for materials with ductile damage

A continuum sensitivity method is developed for thermoplasticity combined with ductile damage at finite strains. The computed sensitivity fields are used within a gradient-based optimization framework for the computational design of metal forming processes for porous materials. The accuracy and effectiveness of the developed updated Lagrangian finite element analysis and design techniques are demonstrated with a number of representative examples. In addition to die design problems, novel preform (shape) design problems are examined for near net shape manufacturing that accounts for the volume change induced during the deformation process.