Methodology of the shape optimization of forging dies

Abstract

In forging process, the dies shape design is the most important step. Reasonable dies shape can not only reduce raw material cost but also improving product quality. Currently there are no packages for the forging process with both simulation and optimization capabilities. So in our research, the main objective is to use the simulation of forging process coupled with an optimization procedure in order to obtain the optimal parameters of the geometry of the dies. To develop this forging process optimization system several numerical tools are required: geometric modelling (CATIA V5™), FE analysis (ABAQUS®), and optimization computation. In this paper, the basic methodology of the forging dies shape optimization method is introduced. In addition to that, with the proposed 2D FE model, we simulated the platting and the forging operation of an industrial example with a hammer machine. The total energy for each simulation is the same. But for applying the energy, we use different number of blows. By doing this test, we can evaluate the influence of the number of blows on the energy dissipation and get more knowledge on the formulation of future optimization problem.