AASERT-92 Experimental Verification of Optimally Designed Metal Forming Processes
Abstract
This research focuses on developing a method for the preform design engineering of material forming processes. In this research, a sensitivity analysis method for preform die shape design in material forming processes is developed using the rigid visco-plastic finite element method. The preform die shapes are represented by cubic B-spline curves. The control points or coefficients of B-spline are used as the design variables. The optimization problem is to minimize the zone where the realized and desired final forging shapes do not coincide. The sensitivities of the objective function, nodal coordinates, and nodal velocities with respect to the design variables are developed in detail. A procedure for computing the sensitivities of history-dependent functions is presented. The remeshing procedure and the interpolation/transfer of the history-dependent parameters, such as effective strain, are stated. The procedures of sensitivity analysis based preform die design are also described. In addition, a method for the adjustment of the volume loss resulting from the finite element analysis is given in order to make the workpiece volume consistent in each optimization iteration. The method developed in this report is used to design the preform die shape of H-shaped forging processes, including plane strain and axisymmetric deformations. The results show that a flashless forging with a complete die fill is realized using the optimized preform die shape.
Document Details
- Document Type
- Technical Report
- Publication Date
- Oct 22, 1996
- Accession Number
- ADA329772
Entities
People
- Ramana V. Grandhi
Organizations
- Wright State University