Numerical simulations of sheet metal forming process based on finite element method (FEM) is widely applied for its powerful capability in forming process prediction. Since there are parameters which could affect the result of forming process, it becomes important to approach a set of parameters to improve the formability. In the present work, first, a comprehensive literature review was made for different optimization methodologies in sheet metal forming process. Then we proposed an optimization methodology using Response Surface methodology (RSM) and Genetic Algorithm (GA) for the optimization of sheet metal forming process, and the theory of RSM and GA are illustrated. The presented method was first applied to an example from literature, the results verified the feasibility of the proposed methodology. Then the methodology was applied to variable binder force optimization of the NUMISHEET 93 2D draw bending problem. The work indicated that the proposed optimization methodology is efficient and universal, which means it can also be applied in other applications of aerospace industry.
