A study for efficiently solving optimisations problems with an increasing number of design variables

Coupling optimisation algorithms to Finite Element Methods (FEM) is a very promising way to achieve optimal metal forming processes. However, many optimisation algorithms exist and it is not clear which of these algorithms to use. This paper investigates the sensitivity of a Sequential Approximate Optimisation algorithm (SAO) proposed in [1–4] to an increasing number of design variables and compares it with two other algorithms: an Evolutionary Strategy (ES) and an Evolutionary version of the SAO (ESAO). In addition, it observes the influence of different Designs Of Experiments used with the SAO. It is concluded that the SAO is very capable and efficient and its combination with an ES is not beneficial. Moreover, the use of SAO with Fractional Factorial Design is the most efficient method, rather than Full Factorial Design as proposed in [1–4]