Validated, internal state variable constitutive models are developed to model the complex multistage forging process and predict the final forging strength and microstructure. Optimization methodologies are then used on a high performance, parallel computer to design the forging dies and temperatures that would meet minimum and maximum strength requirements and result in maximum strength uniformity. Each node on the parallel computer solves a unique finite element simulation including parametric meshing, post-processing and metric determination. Nine shape parameters and one process parameter (temperature) are optimized to reduce strength non-uniformity. The final process design, based on over 360 finite element simulations, meets all material requirements and results in a near uniform strength part.
forging; materials properties; parallel processing; finite element analysis; optimal systems
@inproceedings{ChJoPeKo04,
author = {Michael L. Chiesa and Reese E. Jones and Kenneth J. Perano and Tamara G. Kolda},
title = {Parallel Optimization of Forging Processes for Optimal Material Properties},
booktitle = {NUMIFORM 2004: Proceedings of the 8th International Conference on Numerical Methods in Industrial Forming Processes},
venue = {Columbus, Ohio},
eventdate = {2004-06-13/2004-06-17},
series = {AIP Conference Proceedings},
volume = {712},
pages = {2080-2084},
year = {2004},
doi = {10.1063/1.1766841},
}