A study on the optimal tool shape design in a hot forming process

The optimization technique is applied widely in metal forming processes for various objectives, fold-over and excessive die forces, etc. The aim of this study is to design the optimal tool shape in metal forming processes for the improvement of the mechanical properties of the product by a uniform microstructure. Thus, this study presents a method for designing a tool shape based on uniform microstructure distribution with an optimization technique and the finite element method. The tool shape is controlled using a Bezier curve to define the boundary of the tool. The method proposed in this study is demonstrated with an extrusion die design and preform shape design for uniform microstructure distribution. Finally, to show the validity and effectiveness of the result of this study, an experiment in hot extrusion was performed, and the result of the experiment compared with that of the simulation.