Abstract
Preform shape design for complex forging is an important and intractable aspect in the design of forging process. This paper presents an integrated methodology based on elliptic Fourier analysis (EFA), finite element method (FEM) and genetic algorithms (GA) to determine optimal preform shape. Firstly, an elliptic Fourier analysis, which has the advantages of wide versatility and short design cycle, is adopted as the transformation rule for the first time in this paper. The similarity between elliptic Fourier analysis and plastic forming process is demonstrated theoretically. Meanwhile, the main steps for using elliptic Fourier analysis module to design preform shape are introduced: two-dimensional slice, elliptic Fourier analysis and three-dimensional reconstruction. The preform shapes generated by elliptic Fourier analysis module can be simulated directly in finite element method module. Next, in order to control the deformation amount and material distribution of preform, two sets of design parameters, i.e., shape factor and triaxial scaling factors, are employed to control the preform shape before entering the finite element method module simulation. Then, these design parameters are optimized using the genetic algorithm module. Finally, taking a heavy forging with complex shapes as an example, its optimized design scheme is carried out in real forging production. The results show that the forging is produced without problems of crack, folds, underfilling and unreasonable flash distribution, which validates the effectiveness of the presented methodology. Furthermore, this integrated methodology could be extended to other complex forgings.
Similar content being viewed by others
References
Kang BS, Kim N, Kobayashi S (1990) Computer-aided preform design in forging of an airfoil section blade. Int J Mach Tools Manuf 30(1):43–52. https://doi.org/10.1016/0890-6955(90)90040-P
Gao Z, Grandhi RV (2000) Microstructure optimization in design of forging processes. Int J Mach Tools Manuf 40(5):691–711. https://doi.org/10.1016/S0890-6955(99)00083-8
Park JJ, Hwang HS (2007) Preform design for precision forging of an asymmetric rib-web type component. J Mater Process Technol 187-188:595–599. https://doi.org/10.1016/j.jmatprotec.2006.11.034
Jin Q, Han X, Hua L, Zhuang W, Feng W (2018) Process optimization method for cold orbital forging of component with deep and narrow groove. J Manuf Process 33:161–174. https://doi.org/10.1016/j.jmapro.2018.05.007
Marek H, Jacek Z (2018) Application of the 3D reverse scanning method in the analysis of tool wear and forging defects. Measurement 128:204–213. https://doi.org/10.1016/j.measurement.2018.06.037
Zhao J, Deng Y, Zhang J, Tang J (2019) Effect of forging speed on the formability, microstructure and mechanical properties of isothermal precision forged of Al-Zn-mg-cu alloy. Mater Sci Eng A 767:138366. https://doi.org/10.1016/j.msea.2019.138366
Gao PF, Fei MY, Yan XG, Wang SB, Li YK, Xing L, Wei K, Zhan M, Zhou ZT, Keyim Z (2019) Prediction of the folding defect in die forging: a versatile approach for three typical types of folding defects. J Manuf Process 39:181–191. https://doi.org/10.1016/j.jmapro.2019.02.027
Biba N, Vlasov A, Krivenko D, Duzhev A, Stebunov S (2020) Closed die forging preform shape design using isothermal surfaces method. Proc Manuf 47:268–273. https://doi.org/10.1016/j.promfg.2020.04.219
Ko DC, Kim DH, Kim BM (1999) Application of artificial neural network and Taguchi method to preform design in metal forming considering workability. Int J Mach Tools Manuf 39(5):771–785. https://doi.org/10.1016/S0890-6955(98)00055-8
Wang MH, Xiao GQ, Zhi L, Wang J (2018) Shape optimization methodology of clinching tools based on Bezier curve. Int J Adv Manuf Technol 94(5-8):2267–2280. https://doi.org/10.1007/s00170-017-0987-5
Li F, Chen P, Han J, Deng L, Yi J, Liu Y, Eckert J (2020) Metal flow behavior of P/M connecting rod preform in flashless forging based on isothermal compression and numerical simulation. J Mater Res Technol 9(2):1200–1209. https://doi.org/10.1016/j.jmrt.2019.11.047
Kim N, Kobayashi S (1990) Preform design in H-shaped cross section axisymmetric forging by finite element method. Int J Mach Tools Manuf 30(2):243–268. https://doi.org/10.1016/0890-6955(90)90134-5
Kang BS, Lee JH, Kim BM, Choi JC (1995) Process design in flashless forging of rib/web-shaped plane-strain components by the finite element method. J Mater Process Technol 47(3–4):291–309. https://doi.org/10.1016/0924-0136(95)85005-8
Zhao G, Wright E, Grandhi RV (1997) Sensitivity analysis based preform die shape design for net-shape forging. Int J Mach Tools Manuf 37(9):1251–1271. https://doi.org/10.1016/S0890-6955(96)00087-9
Guan J, Wang GC, Guo T, Song LB, Zhao GQ (2009) The microstructure optimization of H-shape forgings based on preforming die design. Mater Sci Eng A 499(1–2):304–308. https://doi.org/10.1016/j.msea.2007.11.144
Zhao X, Zhao G, Wang G, Wang T (2002) Preform die shape design for uniformity of deformation in forging based on preform sensitivity analysis. J Mater Process Technol 128(1–3):25–32. https://doi.org/10.1016/S0924-0136(02)00054-7
Tang YC, Zhou XH, Chen J (2008) Preform tool shape optimization and redesign based on neural network response surface methodology. Finite Elem Anal Des 44(8):462–471. https://doi.org/10.1016/j.finel.2008.01.007
Roy S, Ghosh S, Shivpuri R (1997) A new approach to optimal design of multi-stage metal forming processes with micro genetic algorithms. Int J Mach Tools Manuf 37(1):29–44. https://doi.org/10.1016/0890-6955(95)00120-4
Ko DC, Kim DH, Kim BM, Choi JC (1998) Methodology of preform design considering workability in metal forming by the artificial neural network and Taguchi method. J Mater Process Technol 80-81(8):487–492. https://doi.org/10.1016/S0924-0136(98)00152-6
Weiß A, Liewald M, Weiß A, Missal N (2018) Manufacture of face gearing – a new production method by means of determined material pre-distribution. Proc Manuf 15:511–518. https://doi.org/10.1016/j.promfg.2018.07.261
Vogel M, Merklein M (2021) Manufacturing of tailored blanks by orbital forming with a two-sided material thickening. J Mater Process Technol 287(2021):116491. https://doi.org/10.1016/j.jmatprotec.2019.116491
Besserer H, Hildenbrand P, Gerstein G, Rodman D, Nünberger F, Merklein M, Maier HJ (2016) Ductile damage and fatigue behavior of semi-finished tailored blanks for sheet-bulk metal forming processes[J]. J Mater Eng Perform 25(3):1136–1142. https://doi.org/10.1007/s11665-016-1908-8
Vazquez V, Altan T (2000) Die design for flashless forging of complex parts. J Mater Process Technol 98(1):81–89. https://doi.org/10.1016/S0924-0136(99)00308-8
Sedighi M, Tokmechi S (2008) A new approach to preform design in forging process of complex parts. J Mater Process Technol 197(1–3):314–324. https://doi.org/10.1016/j.jmatprotec.2007.06.043
Park JJ, Rebelo N, Kobayashi S (1983) A new approach to preform design in metal forming with the finite element method. Int J Mach Tools Manuf 23(1):71–79. https://doi.org/10.1016/0020-7357(83)90008-2
Zhao G, Wright E, Grandhi RV (1995) Forging preform design with shape complexity control in simulating backward deformation. Int J Mach Tools Manuf 35(9):1225–1239. https://doi.org/10.1016/0890-6955(94)00117-3
Zhao G, Wright E, Grandhi RV (1996) Computer aided preform design in forging using the inverse die contact tracking method. Int J Mach Tools Manuf 36(7):755–769. https://doi.org/10.1016/0890-6955(96)00123-X
Zhao G, Zhao Z, Wang T, Grandhi RV (1998) Preform design of a generic turbine disk forging process. J mater process Technol 84(1-3):193-201. 1https://doi.org/10.1016/S0924-0136(98)00221-0
Zhao G, Wang G, Grandhi RV (2002) Die cavity design of near flashless forging process using FEM-based backward simulation. J Mater Process Technol 121(2):173–181. https://doi.org/10.1016/S0924-0136(01)00998-0
Lee JH, Kim YH, Bae WB (1997) An upper-bound elemental technique approach to the process design of asymmetric forgings. J Mater Process Technol 72(1):141–151. https://doi.org/10.1016/S0924-0136(97)00145-3
Lee JH, Kim YH, Bae WB (1997) A study on flash- and flashless-precision forging by the upper-bound elemental technique. J Mater Process Technol 72(3):371–379. https://doi.org/10.1016/S0924-0136(97)00197-0
Lee SR, Lee YK, Park CH, Yang DY (2002) A new method of preform design in hot forging by using electric field theory. Int J Mech Sci 44(4):773–792. https://doi.org/10.1016/S0020-7403(02)00003-6
Wang X, Li F (2009) A quasi-equipotential field simulation for preform design of P/M superalloy disk. Chinese J Aeronaut 22(1):81–86. https://doi.org/10.1016/S1000-9361(08)60072-2
Cai J, Li F, Liu T (2011) A new approach of preform design based on 3D electrostatic field simulation and geometric transformation. Int J Adv Manuf Technol 56(5–8):579–588. https://doi.org/10.1007/S00170-011-3216-7
Guan Y, Bai X, Liu M, Song L, Zhao G (2014) 3D preform design in forging process based on quasi-quipotential field and response surface methods. Process Eng 81:468–473. https://doi.org/10.1016/j.proeng.2014.10.024
Guan Y, Bai X, Liu M, Song L, Zhao G (2015) Preform design in forging process of complex parts by using quasi-equipotential field and response surface methods. Int J Adv Manuf Technol 79(1–4):21–29. https://doi.org/10.1007/S00170-014-6775-6
Tao Y, Zhou J, Cao J, Luo Y, Chen B (2015) Optimization design preform billet shape of 7050 aluminum alloy giant plane forgings based on electric field method and MBC toolbox. Int J Adv Manuf Technol 81(1–4):231–240. https://doi.org/10.1007/S00170-015-7149-4
Chen H, Guan Y, Liu M, Li Y, Zhai J, Lin J (2020) Preform optimization of a brake drum part based on quasi-equipotential field and response surface methods. Proc Manuf 50:276–279. https://doi.org/10.1016/j.promfg.2020.08.051
Kuhl FP, Giardina CR (1982) Elliptic Fourier features of a closed contour. Comput Graph Image Process 18(3):236–258. https://doi.org/10.1016/0146-664X(82)90034-X
Diaz G, Zuccarelli A, Pelligra I, Ghiani A (1989) Elliptic Fourier analysis of cell and nuclear shapes. Comput Biomed Res 22(5):405–414. https://doi.org/10.1016/0010-4809(89)90034-7
Neto JC, Meyer GE, Jones DD, Samal AK (2006) Plant species identification using elliptic Fourier leaf shape analysis. Comput Electron Agric 50(2):121–134. https://doi.org/10.1016/j.compag.2005.09.004
Tracey SR, Lyle JM, Duhamel G (2006) Application of elliptical Fourier analysis of otolith form as a tool for stock identification. Fish Res 77(2):138–147. https://doi.org/10.1016/j.fishres.2005.10.013
Jeong Y, Radke RJ (2007) Reslicing axially sampled 3D shapes using elliptic Fourier descriptors. Med Image Anal 11(2):197–206. https://doi.org/10.1016/j.media.2006.12.003
Valčić M, Prpić-Oršić J (2016) Hybrid method for estimating wind loads on ships based on elliptic Fourier analysis and radial basis neural networks. Ocean Eng 122:227–240. https://doi.org/10.1016/j.oceaneng.2016.06.031
Caple JM, Byrd JE, Stephan CN (2018) The utility of elliptical Fourier analysis for estimating ancestry and sex from lateral skull photographs. Forensic Sci Int 289:352–362. https://doi.org/10.1016/j.forsciint.2018.06.009
Tuset VM, Galimany E, Farrés A, Marco-Herrero E, Otero-Ferrer JL, Lombarte A, Ramón M (2020) Recognising mollusc shell contours with enlarged spines: wavelet vs elliptic Fourier analyses. Zoology 140:125778. https://doi.org/10.1016/j.zool.2020.125778
Haipeng P, Tianrui Z (2007) Generation and optimization of slice profile data in rapid prototyping and manufacturing. J Mater Process Technol 187-188:623–626. https://doi.org/10.1016/j.jmatprotec.2006.11.221
Lee SH, Ahn DG, Yang DY (2002) Surface reconstruction for mid-slice generation on variable lamination manufacturing. J Mater Process Technol 130-131:384–389. https://doi.org/10.1016/S0924-0136(02)00730-6
Koc B, Ma Y, Lee YS (2000) Smoothing STL files by max-fit biarc curves for rapid prototyping. Rapid Prototyping J 6(3):186–205. https://doi.org/10.1108/13552540010337065
Desbrun M, Meyer M, Schröder P, Barr AH (1999) Implicit fairing of irregular meshes using diffusion and curvature flow. Proc SIGGRAPH99:317–324. https://doi.org/10.1145/311535.311576
Chitkara NR, Bhutta MA (1996) Near-net shape forging of spur gear forms: an analysis and some experiments. Int J Mech Sci 38(8–9):891–916. https://doi.org/10.1016/0020-7403(95)00097-6
Tomov BI, Gagov VI (1999) Modelling and description of the near-net-shape forging of cylindrical spur gears. J Mater Process Technol 92-93:444–449. https://doi.org/10.1016/S0924-0136(99)00169-7
Chitkara NR, Kim YJ (2001) Near-net shape forging of a crown gear: some experimental results and an analysis. Int J Mach Tools Manuf 41(3):325–346. https://doi.org/10.1016/S0890-6955(00)00083-3
Cai J, Dean TA, Hu ZM (2004) Alternative die designs in net-shape forging of gears. J Mater Process Technol 150(1–2):48–55. https://doi.org/10.1016/j.jmatprotec.2004.01.019
Petrov P, Perfilov V, Stebunov S (2006) Prevention of lap formation in near net shape isothermal forging technology of part of irregular shape made of aluminium alloy A92618. J Mater Process Technol 177(1–3):218–223. https://doi.org/10.1016/j.jmatprotec.2006.03.206
Lu B, Ou H, Armstrong CG, Rennie A (2009) 3D die shape optimisation for net-shape forging of aerofoil blades. Mater Design 30(7):2490–2500. https://doi.org/10.1016/j.matdes.2008.10.007
Takemasu T, Vazquez V, Painter B, Altan T (1996) Investigation of metal flow and preform optimization in flashless forging of a connecting rod. J Mater Process Technol 59(1–2):95–105. https://doi.org/10.1016/0924-0136(96)02290-X
Gontarz A, Pater Z, Weroñski W (2004) Head forging aspects of new forming process of screw spike. J Mater Process Technol 153-154:736–740. https://doi.org/10.1016/j.jmatprotec.2004.04.164
Kim H, Sweeney K, Altan T (1994) Application of computer aided simulation to investigate metal flow in selected forging operations. J Mater Process Technol 46(1–2):127–154. https://doi.org/10.1016/0924-0136(94)90107-4
Kim HR, Seo MG, Bae WB (2002) A study of the manufacturing of tie-rod ends with casting/forging process. J Mater Process Technol 125:471–476. https://doi.org/10.1016/S0924-0136(02)00323-0
Grass H, Krempaszky C, Werner E (2006) 3-D FEM-simulation of hot forming processes for the production of a connecting rod. Comput Mater Sci 36(4):480–489. https://doi.org/10.1016/j.commatsci.2005.06.003
Deng L, Ren Z, Guo P, Jin J, Wang X, Li J (2019) Precision forming of long-axis forgings with rib-web sections via billet optimization based on flow characteristics. Int J Lightweight Mater Manuf 2(2):97–106. https://doi.org/10.1016/j.ijlmm.2019.04.006
Kim TJ, Chitkara NR (2001) Determination of preform shape to improve dimensional accuracy of the forged crown gear form in a closed-die forging process. Int J Mech Sci 43(3):853–870. https://doi.org/10.1016/S0020-7403(00)00020-5
Liu J, Cui Z (2009) Hot forging process design and parameters determination of magnesium alloy AZ31B spur bevel gear. J Mater Process Technol 209(18–19):5871–5880. https://doi.org/10.1016/j.jmatprotec.2009.06.015
Razanica S, Malakizadi A, Larsson R, Cedergren S, Josefson BL (2020) FE modeling and simulation of machining alloy 718 based on ductile continuum damage. Int J Mech Sci 171:105375. https://doi.org/10.1016/j.ijmecsci.2019.105375
Acknowledgements
This work was supported by the National Natural Science Foundation of China (Grant No. 51975072).
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that they have no conflict of interest.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Liu, C., Xu, W., Wang, Y. et al. Optimal design of preform shape based on EFA-FEM-GA integrated methodology. Int J Mater Form 14, 1043–1056 (2021). https://doi.org/10.1007/s12289-021-01620-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12289-021-01620-0