Numerical Simulation and Optimization of the Forging Process

Abstract : The objective of optimizing automatically industrial forming conditions in order to achieve a desired objective goal is now possible due to continuous increase of fast and parallel computers. Optimization requires that the computer simulation is accurate enough, that the material behavior is precisely identified and that the optimization parameters are properly selected. To achieve the first goal, the fundamental mechanical assumptions and the basic principles of three-dimensional finite element discretization are briefly recalled. Several important numerical developments for efficient computation of large plastic deformation are mentioned. The second requirement is fulfilled not only by experimental tests and identification of the material parameters of the constitutive law. Is it also necessary to predict the possible onset of defects such as cracking by introducing damage modeling. Before optimization, a parameter sensitivity analysis must be performed in order to select the most important factors: shape of the preform, tools geometry, etc. The practical optimization can be carried out by a evolutionary algorithm technique associated with a surface response method. Several examples of applications will be presented to illustrate the effectiveness of the procedure with the FORGE3 computer code. The optimization criterion can be on the forming force, on the material weight or on the final strength of the part.