Reduction of Stages in Multi-Stage Metal Forming Process Based on Numerical Optimization in Conjunction with FE Simulation

2007 ◽  
Vol 340-341 ◽  
pp. 767-772
Author(s):  
Ryutaro Hino ◽  
Akihiko Sasaki ◽  
Fusahito Yoshida ◽  
Vassili V. Toropov
Keyword(s):  
Design Optimization ◽  
Process Design ◽  
Metal Forming ◽  
Numerical Optimization ◽  
Fe Simulation ◽  
Design Technique ◽  
Forming Process ◽  
Multi Stage ◽  
Metal Forming Process ◽  
Stage Process

In this study, a new simulation-based design technique for multi-stage metal forming process is developed with special emphasis on reduction of stages in the process. The developed design technique is an iterative design optimization, which is based on response-surface-based numerical optimization and finite element analysis of the process. The design procedure starts with the initial rough process design. To eliminate one stage in the multi-stage process, the new optimum process design is determined based on the former process design by using numerical optimization in conjunction with FE simulation. This design optimization step is repeated, reducing the stages one by one, until the possible minimum number of stages is reached. The developed design technique is applied to stage reduction of a 3-stage axisymmetric forging process of aluminum billet. We can confirm that a new 2-stage process design is determined successfully and the developed design optimization technique is effective to reduce stages in multi-stage forming process.

Experimental Investigations and Automatic Numerical Optimization of a Bulk Metal Forming Process to Avoid Forging Folds

2015 ◽  
Vol 651-653 ◽  
pp. 305-310
Author(s):  
Bernd Arno Behrens ◽  
Sonda Moakhar Bouguecha ◽  
Milan Vucetic ◽  
Anas Bouguecha ◽  
Mohammad Kazhai
Keyword(s):  
Process Parameters ◽  
Process Design ◽  
Numerical Optimization ◽  
Experimental Investigations ◽  
Forming Process ◽  
Element Analysis ◽  
Complex Processes ◽  
Metal Forming Process ◽  
Fold Formation ◽  
Indispensable Tool

The detection of process failures in earlier design stages is essential for preventing high additional costs and a loss of time. Here, the finite element analysis (FEA) is an inherent part of the process design. This work represents numerical and experimental investigations, which were carried out in order to identify factors that influence the fold formation in an upsetting process of hollow parts, i.e. different forging velocities, different materials or the friction. The experimental results were compared with the numerical simulations. Based on these investigations, an automatic optimization model was created, which is the focus of this work. It allows varying and optimizing the experimentally determined process parameters, influencing the fold formation, automatically with the aim to produce a workpiece free of folds. For this purpose the commercial Software-System Forge (Transvalor) was used. The results of this work provide basic information for the development of complex processes. It can be shown that the automatic numerical optimization is an indispensable tool for the process design. It helps determining optimal process parameters individually and avoiding extensive trial and error investigations and hence a loss of time and costs.

Research on the Metal Forming Process of the Muffler Tube Using Finite Element Method

2008 ◽  
Vol 385-387 ◽  
pp. 841-844
Author(s):  
Kyu Taek Han ◽  
Yi Jiong Jin
Keyword(s):  
Finite Element ◽  
Process Design ◽  
Metal Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Punch Radius ◽  
Metal Forming Process ◽  
Fracture Theory ◽  
Simulation Results ◽  
Fourth Component

A muffler is an important part used to reduce noise and to purify exhaust gas in cars and heavy equipments. Recently there has been a growing interest in the designing and manufacturing the muffler tube due to the strict environmental regulations. The technique of perforating on the muffler tube has been largely affected by the shear clearance. And considering the concentration of the force around the punch edge, it is essential to reduced it through the punch radius. In this research, finite element analysis has been carried out to predict optimal forming conditions of the muffler tube using DEFORMTM-3D. In analysis, using one-fourth component of the punch and die, metal forming process is simulated and Cockcroft-Latham ductile fracture theory is used. According to the simulation results, when the shear clearance is 0.04mm, the punch radius is 0.05mm and the value of plate holder force is 250KN, the relation of load-stroke for punch is optimized. Also the burr is minimized and optimal shear section is obtained. The simulation results are reflected to the forming process design for the muffler tube.

A Knowledge-Based Engineering Method to Integrate Metal Forming Process Design and Simulation

1994 ◽  
Author(s):  
Tom Robertson ◽  
Biren Prasad ◽  
Ravi Duggirala
Keyword(s):  
Process Design ◽  
Metal Forming ◽  
Computer Aided Design ◽  
Forming Process ◽  
Element Analysis ◽  
Forming Simulation ◽  
Knowledge Based ◽  
Metal Forming Process ◽  
Knowledge Based Engineering ◽  
Integrate Design

Abstract The integration of Computer Aided Design (CAD) and Finite Element Analysis (FEA) tools is an important consideration in metal forming design. Traditionally, engineering functions such as classical analysis, FEA, CAD, etc. are performed separately. The emergence of knowledge-based engineering (KBE) tools and its language-based structure provides a basis to integrate design functions. This paper presents a KBE system which effectively integrates metal forming process design and FEA analysis by automating the pre-processing required for metal forming simulation for two dimensional problems. The method will be applicable to 3D problems as FEA technology improves.

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