Analysis and optimal design of forging preforming for I-shaped forgings

Abstract The optimal design of forging preforming is the key to improving forging quality and productivity. Taking an I-shaped forging as a research object, an approach to optimize two-dimensional preform shape is employed. The mathematical model of multi-objective optimization in forging forming simulation is established, and the forming load and die wear are used as the objective functions to optimize the design. Two forms of straight line and circular arc are designed for the shape of the deformation area of the preforming die. With the aid of the finite element simulation software, the process of preforming and finishing forging by using the preformed die with different design variables and different parameters is simulated. Simulation results show that the best optimization results can be achieved when the linear angle is 53.5° and the circular arc radius is 66 mm. After optimization, the load drops by about 36 percent by adopting the circular arc shape, and by about 76 percent by adopting the straight-line shape. The die wear depth decreases and the wear zones become more balanced after optimization. Numerical results prove that this approach is effective in designing the optimal preform shape in forging.