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2D-based optimization of closed die forging using the variable gutter technique and response surface methodology

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Abstract

In this paper, a new method of simultaneous die and preform optimization is proposed for closed die forging of nearly plane-strain components with complex geometry along their axes. In this method, using two-dimensional finite element simulations and the response surface method, optimal values for the width and thickness of the flash land and the amount of additional material in each of the main sections are obtained. Accordingly, using the variable gutter technique, the preform and dies are designed based on the optimization goal. To investigate the usefulness of the method in three optimization approaches, including the minimum forging force, the minimum excess material, and a balance between the forging force and the excess material, the values of forging load, waste material, die stress, deformation, heat distribution, material flow, and die wear were determined numerically and compared to the conventional method. The results showed that the presented method can save up to 60% in forging force and up to 51.5% in excess material compared to the conventional method. It can also minimize die wear by up to 74% and die stress by up to 50%. Finally, the numerical results showed that a balanced mode between the minimum forging load and the minimum excessive materials can be chosen as the most appropriate selection for practical purposes.

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Authors and Affiliations

  1. Institute of Materials and Energy, Isfahan, Iran

    Hamed Sheikhbahaee & S. Javid Mirahmadi

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  1. Hamed Sheikhbahaee
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Hamed Sheikhbahaee designed the research strategy and performed computer modeling and simulation. S. Javid Mirahmadi conducted data analysis and manuscript editing.

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Correspondence to Hamed Sheikhbahaee.

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Sheikhbahaee, H., Mirahmadi, S.J. 2D-based optimization of closed die forging using the variable gutter technique and response surface methodology. Int J Interact Des Manuf (2024). https://doi.org/10.1007/s12008-024-01842-x

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