Optimization of hot forging process by smart design and numerical analysis method

In this time being, the trend in manufacturing process is toward fast and mass productions. Forging process is classified as one of the most important methods to produce a semi and final products with suitable durability. In deformation proses like forging, the problems of high sticking and frictional contact between the workpeice and tools during and after the process need to be solved. Also it’s very important to develop analysis and simulation method for optimizing the products and increase the tools life by avoiding and minimize the stresses concentration in some weak points. In this research; finite element software ABAQUS/ CAE have been conducted for analysis and simulation this deformation process. This design and manufacturing study including a forging process for a symmetric and cylindrical product with constant wall thickness. The main opjectives of this work is to develop a new design and build a virtual experimental model to minimize the generation stresses in hot forging products through controlling some parameters and variables. An axis-symmetric model of finite element (FE) was established for modelling and simulation this process. As a results; it’s found that due to high deflections of tools, dies and machines which caused by the forging forces; the generation stresses and stiffness of tools are the important variables on the overall deformation process. It’s concluded from this study that; it’s very important to link between the manufacturing considerations and design aspects in any effective optimization. Analysis and simulations results were verified and the optimization presented was carried out.