Design of optimal preforms for forged parts by use of stochastic optimization methods

• Applicants: Professor Dr.-Ing. Bernd-Arno Behrens; Professor Dr.-Ing. Ludger Overmeyer
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: from 2014 to 2018
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 252362634

The development of forging stages for die forging processes is mainly based on the experience of the design engineer. A verification of the forging stages is done by use of FEA and forging trials. In the original project, on which this transfer project is based, a process chain has been developed in which the preform has been designed computer-aided, based on the final geometry of the part. Variations and cyclic optimizations were done by an evolutionary algorithm (EA). The results were rated by use of FEA. Based on the results of the original project, this transfer project shall extend the use of this algorithm to more complex parts, by use of a modularized (partial) view of the parts, to transfer the basic knowledge to industrial use. Further, the results of the EA shall be improved by an iterative adaption of the internal rating function in the EA to the results of the FEA. The adaption will be performed by analysis of the FE results of the preforms generated by the EA. Based on these analysis corrective parameters will be derived, which are considered in the rating of EA generation.In order to reach realistic results, forging trials with a conventional process chain and a process chain with a preform optimized by the EA will be performed at the industrial partner. The results will be used to verify the design of the preform and the whole process.

• DFG Programme: Research Grants (Transfer Project)
• Participating Institution: Hammerwerk Fridingen GmbH; Umform- und Bearbeitungstechnik