Shape optimization of forming dies

Metal forming is one of the most important production technologies in modern industry. The companies have a constant need to increase the quality of the products and to decrease the production costs. In the design of a metal forming process, the only factors that are known are the final product shape and the material. Goal of process design in forging is to produce industrial parts with high quality, precise dimensions in a most economical way. Using FEA based numerical simulation a wide range of mechanical and thermal data can be obtained, allowing the numerical optimization of forging. In this book an integrated modelling approach is formulated, where optimal processing conditions such as die velocity, billet and die temperatures are established in conjunction with an optimized preform shape based on the desired end product. The objectives of preform optimization are control over die stresses, complete filling and good microstructure. The proposed design scheme helps to achieve the desired level of control needed to avoid costly production problems such as: incomplete die fill, surface defects, excessive flash, large die loads and accelerated die wear in metal forming process.