The optimal design of the tools in bulk metal forming is a crucial task in the early design phase and greatly affects the final accuracy of the parts. The process of tool geometry assessment is resource- and time-consuming, as it consists of experience-based procedures. In this paper, a compensation method is developed with the aim to reduce geometrical deviations in hot forged parts. In order to simplify the transition process between the discrete finite-element (FE) mesh and the computer-aided-design (CAD) geometry, a strategy featuring an equivalent surrogate model is proposed. The deviations are evaluated on a reduced set of reference points on the nominal geometry and transferred to the FE nodes. The compensation approach represents a modification of the displacement-compatible spring-forward method (DC-SF), which consists of two elastic FE analyses. The compatible stress originating the deviations is estimated and subsequently applied to the original nominal geometry. After stress relaxation, an updated nominal geometry of the part is obtained, whose surfaces represent the compensated tools. The compensation method is verified by means of finite element simulations and the robustness of the algorithm is demonstrated with an additional test geometry. Finally, the compensation strategy is validated experimentally.

在大块金属成型中，模具的最佳设计是早期设计阶段的关键任务，并且极大地影响了零件的最终精度。刀具几何形状评估的过程既耗时又耗时，因为它由基于经验的程序组成。本文提出了一种补偿方法，旨在减少热锻件的几何偏差。为了简化离散有限元（FE）网格和计算机辅助设计（CAD）几何之间的过渡过程，提出了一种具有等效替代模型的策略。在名义几何上的一组减少的参考点上评估偏差，并将其转移到FE节点。补偿方法是对位移兼容弹簧前移方法（DC-SF）的修改，其中包含两个弹性有限元分析。估计源自偏差的兼容应力，然后将其应用于原始标称几何形状。应力松弛后，将获得零件的更新标称几何形状，该零件的表面代表补偿后的工具。该补偿方法通过有限元仿真进行了验证，并通过额外的测试几何结构证明了该算法的鲁棒性。最后，通过实验验证了补偿策略。该补偿方法通过有限元仿真进行了验证，并通过额外的测试几何结构证明了该算法的鲁棒性。最后，通过实验验证了补偿策略。该补偿方法通过有限元仿真进行了验证，并通过额外的测试几何结构证明了该算法的鲁棒性。最后，通过实验验证了补偿策略。