Research On Preform Optimization Design Method In Forging Process Based On Response Surface Method

The goal of forging production is to make the best with the lowest cost. Researchers always focus on how to reduce the cost of forging production, energy consumption and materials waste and improve the quality of the forging in the research field of forging. Preform design is an important factor affecting the quality of forgings, is also a difficulty in the design of forging process. With the rapid development of the national economy, the development of an effective preform method is imperative, the preform optimization design is also more and more applied to practical engineering. So to research the pre forging shape optimization, improve the comprehensive performance of forgings, is very meaningful.Firstly, in the case of BC2270A sprockets, this paper introduces the general experience of trial and error method preform design method, numerical simulation analysis for forging preform process has carried on the detailed introduction. Based on BC2270A sprocket, and puts forward three kinds of preform design, through the numerical simulation analysis of the three design schemes, found that the third design scheme, which is final forging, ring pre blocking the chain wheel forming effect is good, and the annular pre blocking in the ring rolling process is more convenient and easy to control. Finally, the forging process of B2270A sprockets is:baiting-upsetting-punching-expanding (or ring rolling)-finish forging-machining, and finally got the B2270A sprocket forgings.The paper considers the H section forgings as the object of the optimization, introduced the preform optimization design based on the response surface method. The paper Controls several key geometric dimensions of the forging, Realized the parametric expression of the pre forging. Based on response surface method arrangement CCD test, can reduce the test sample size, thus greatly reducing the optimal design of the computational cost; Next, use the Deform numerical simulation method for calculation test sample points; Finally, considered the conditions of the mold filling and load value as the evaluation indexes, namely as objective function, constructed a second order response surface approximation model, through the particle swarm algorithm(PSO) to response the following second-order polynomial function for optimization operation.This article also finished the preform optimization design of bucket teeth with complicated three-dimensional shape with response surface method, discussed the multivariable optimization design. For five geometric parameters (L1, L2, L3, L4, α), we used PB design to select the most significant factors:L2, L4and α, aiming at the deformation uniformity, local fill with forgings as constraint conditions, do the preform optimization design research. After optimization, the optimization design based on deformation uniformity, forging the equivalent strain distribution more uniform, effectively improve the quality of the final forging optimization effect is obvious. The metal flow behaviors and deformation mechanics characteristics of the bucket tooth forging were presented, which provided guidance significance for the process and the designs of die.