Process-integrated Compensation of Geometrical Deviations for Bulk Forming

In many cases the design and development of bulk forming processes bases on inefficient trial-and-error procedures consisting of various iterations of numerical and real tests. To address this issue, a new numerical strategy to compensate systematic deviations of bulk-formed parts is deduced. Due to a parameter-based approach, control points allow for a direct mapping between the die and the workpiece. Thus, based on the required part shape, it is possible to directly adjust the die, where any kind of geometrical input data can be provided to derive a systematic compensation. The purely geometrical approach takes into account the entirety of systematical effects regarding deviations in bulk forming. The proposed concept is shown theoretically and moreover validated as well as verified utilizing deviation data of three manufactured industrial bulk-forming parts.

[1]  Cecil Armstrong,et al.  3D die shape optimisation for net-shape forging of aerofoil blades , 2009 .

[2]  F. Klocke,et al.  Numerical shape optimization of cold forging tools by means of FEM/BEM simulation , 2017 .

[3]  Cecil Armstrong,et al.  An FE simulation and optimisation approach for the forging of aeroengine components , 2004 .

[4]  Jean-Loup Chenot,et al.  OPTIMAL DESIGN FOR NON-STEADY-STATE METAL FORMING PROCESSES. II: APPLICATION OF SHAPE OPTIMIZATION IN FORGING , 1996 .

[5]  Bernd-Arno Behrens,et al.  Process Design and Tooling Configuration for Precision Forging of High Performance Components , 2009 .

[6]  J. Ponthot,et al.  A cascade optimization methodology for automatic parameter identification and shape/process optimization in metal forming simulation , 2006 .

[7]  R. Haftka,et al.  Structural shape optimization — a survey , 1986 .

[8]  Yi Qin,et al.  Analysis, evaluation and compensation of component-errors in the nett-forming of engineering components , 2000 .

[9]  Jean-Loup Chenot,et al.  OPTIMAL DESIGN FOR NON‐STEADY‐STATE METAL FORMING PROCESSES—I. SHAPE OPTIMIZATION METHOD , 1996 .

[10]  Yong Shao,et al.  Topology-based preform design optimization for blade forging , 2016 .

[11]  R. Balendra.  Overview of “Die-cavity elasticity considerations for nett-forming (DICAVITY)” , 2001 .

[12]  Hui Long,et al.  Evaluation of elasticity and temperature effects on the dimensional accuracy of back-extruded components using finite element simulation , 1998 .

[13]  Robert Schulte,et al.  A non-invasive form finding method with application to metal forming , 2016, Prod. Eng..

[14]  Yunliang Ding,et al.  Shape optimization of structures: a literature survey , 1986 .

[15]  Mark S. Shephard,et al.  Towards Realistic Automated 3D Modelling of Metal Forming Problems , 1999, Engineering with Computers.

[16]  R. Balendra.  Nett-shape forming: state-of-the-art , 2001 .

[17]  Kang Ji,et al.  Determination of Processing Windows for the Hot Stamping of AA7075 , 2016 .

[18]  Cecil Armstrong,et al.  Die Shape Compensation in Hot Forging of Titanium Aerofoil Sections , 2002 .

[19]  Hengan Ou,et al.  Finite element modelling and optimisation of net-shape metal forming processes with uncertainties , 2012 .

[20]  V. Braibant,et al.  Shape optimal design using B-splines , 1984 .

[21]  Yongnam Kwon,et al.  Analysis of the elastic characteristics at die and workpiece to improve the dimensional accuracy for cold forged part , 2004 .

[22]  Yeh-Liang Hsu,et al.  A review of structural shape optimization , 1994 .

[23]  Andrzej Rosochowski,et al.  Secondary yielding of forged components due to unloading , 2001 .

[24]  R. Balendra,et al.  Temperature-related errors on aerofoil section of turbine blade , 2001 .