A new approach to preform design in forging process of complex parts

Geometrical design of preform in forging process of complex parts has great effects on the forging load and material wastes. This paper by proposing a new algorithm, tries to present a suitable method for practical designation of preforms for complex parts. The proposed algorithm includes two phases named preliminary preform selection and improvement of the preform geometry. In the second phase the finite volume method (FVM) and parametric design method are used. Also a control criterion (CN) has been suggested in order to control the improvement process. By replacing the time consuming “Remeshing” process, which is necessary by the finite element method (FEM) approach at large deformations with FVM, the ability of material flow simulation is increased. The parametric design method eases the numerous changes of preform geometry. These can lead to cost and time reduction in the stages of designing an improved preform. The capability of the proposed algorithm for preform design is evaluated by selecting an aeronautical part so-called Master Support. The results for two various die sets show that waste materials can be totally reduced to 5.1 and 7.3% while the forging loads are also decreased. It leads toward the complete and near-flashless forging process with a well-improved preforms for both die sets.