A new algorithm for reduction of number of press-forming stages in forging processes using numerical optimization and FE simulation

This study presents a new simulation-based technique for the optimum design of a multi-stage forging process aiming at reduction of the number of press-forming stages. This iterative design technique involves response-surface-based numerical optimization and a finite element analysis of the process. The design procedure starts with an initial process design that is deemed too conservative, i.e. allows to arrive at the desired product but involves an excessive number of stages. To obtain a better process design, one stage of the existing multi-stage process is eliminated using numerical optimization in conjunction with an FE simulation. This is repeated by reducing the number of stages one by one until the minimum possible number of stages is reached. This design technique is applied to stage reduction of a three-stage forging process of an axisymmetric aluminum billet. It is confirmed that a new two-stage process design is obtained successfully and the developed design optimization technique showed its effectiveness in reduction of the number of press-forming stages in a multi-stage forming process.