Modelling of a thermomechanically coupled forming process based on functional outputs from a finite element analysis and from experimental measurements

In this paper, measurements from experiments and results of a finite element analysis (FEA) are combined in order to compute accurate empirical models for the temperature distribution before a thermomechanically coupled forming process. To accomplish this, Design and Analysis of Computer Experiments (DACE) is used to separately compute models for the measurements and the functional output of the FEA. Based on a hierarchical approach, a combined model of the process is computed. In this combined modelling approach, the model for the FEA is corrected by taking into account the systematic deviations from the experimental measurements. The large number of observations based on the functional output hinders the direct computation of the DACE models due to the internal inversion of the correlation matrix. Thus, different techniques for identifying a relevant subset of the observations are proposed. The application of the resulting procedure is presented, and a statistical validation of the empirical models is performed.