Research And Realization Of Multi-station Forging Optimization Technology Based On DOE And 3D Numeric Simulation

The multi-station forging process is a kind of method to produce near net-shape products which could overcome some problems of traditional cold/hot forging process, such as occupation of equipment, heat treatment between processes. The multi-station forging process could improve the productivity, reduce energy consumption and improve the quality of forging process. It is an important direction of forging process. Forging process and die design are very important in the forging products design, because it directly affects the quality, cost and manufacturing efficiency of the final products, and the life of forging die as well as equipment protection. In the environment of the severe competition and market globalization, how to improve the quality of forging peocess and die design, to increase the grade of integration, systematization, intellectualization for forging process design and ultimately leap from experience design to scientific design are the desire of forging-process-die designer. In order to meet the requirements of modern manufacture of the forging die design, for example, short cycle, high quality and low cost, it was necessary to introduce advanced design theories and methods as well as computer technologies, especially intelligence design technology, FEM and design optimization techniques into traditional forging die design fields.This dissertation mainly focuses on three aspects. The first aspect concerns the Design of Experiment (DOE), FEM and optimization method of multi-station forging process, build the modeling of the process parameter of muilt-station forging to optimize the process. Secondly, the Taguchi and Latin Hypercube Sampling (LHS) experimental methods were applied in this system to improve the optimization efficiency. Thirdly, take a deeply study on the CAD/CAE integration technology.According to the characteristics of muilt-station forging process, this optimization system is developed, and the functionality of each module is discussed, and the data flow between each module is introduced. Several optimization techniques have been used in this system, including approximation model method, mathematic optimization method and design of experiment. Some kinds of interface developing technology have also been applied to the system, including Open/API of UG NX, text mode of DEFORM 3D, Office Excel 2003, and M-file DLL method of Matlab.Take gear part for example, choose volume of areas and loads of each stage as object function and preform geometry parameters as design variables, designing the experiment by LHS method and building model by response surface method. The result showed the significantly reduction of the loads and improvement of the forming situation, also proved this system is effective in the multi-station forging process optimization. The system is run to optimize the gear part to prove the correctness and effectiveness of this system.