PREFORM SHAPE OPTIMIZATION IN FORGING PROCESS

In this research, preform shape optimization in forging process of a geometrically complex shape is investigated using the reduced basis technique (RBT) which is coupled by Taguchi design of experiments and finite element method is presented. The RBT is a weighted combination of several trial shapes to find the best combination using the weights for each billet shape as the design variables. A multi-level design process is presented to find suitable basis shapes at each level that can be used in the reduced basis technique. Each level is treated as a separate optimization problem until the required objective is achieved. Flash, i.e. excess material, is a industry requirement. The optimization process is started with simple basis shapes that are defined by their shape co-ordinates.

Keywords:

Preform shape optimization , Reduced basis technique , Taguchi design of experiment method , Finite element method