Forging Simulation & Preform Design: Struggling with…
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Forging Simulation & Preform Design: Struggling with extreme forces and die deformation
Hi everyone,
I'm currently working on my diploma thesis, which focuses on the determination and simulation of the forging process for a specific component (shown in the attached images). The task also specifies minimization of forging steps and also some temperature limitations are presented.
I've already run about 100 simulations, but I am completely stuck trying to find the right preform geometry. I have tried multiple approaches and optimization algorithms, including the electrostatic field method and simple moving averages, but nothing seems to give a successful result.
I keep running into two major issues:
1. Material Flow Defects: I am experiencing severe issues with Gartfield field parameter.
2. Extreme Forming Forces: The required tonnage/force is incredibly high, which ultimately results in the plastic deformation of the tooling/die—which is, of course, unacceptable.
Also literature specifically dedicated to forging preform determination and optimization methods seems to be very limited.
I would deeply appreciate any advice or insight:
* Has anyone encountered a similar issue where the preform design causes either severe defects or tool-deforming forces?
* Can anyone recommend good literature, textbooks, or research papers focusing on preform design which will literarly guide me through the whole process of designing it (I just can´t find any)?
* Are there alternative simulation strategies or geometric approach rules I might have overlooked?
I am using QForm UK software.
**Please help me I am completely lost and I have already lost 1 month with preform design, it seems like nothing works for me. I am seeking for any kind of advice and I truly need help. Thanks in advance.**
If anyone would like to see more content about the problem I will kindly send it.
Shape of preform with Gartfield field https://preview.redd.it/vo1f6zi0086h1.png?width=1055&format=png&auto=webp&s=43e8b5c941fd5fde7ed6305e10d5b66ad6fcbc22
Shape of final forging with Gartfield field https://preview.redd.it/vhk6v6s6086h1.png?width=1016&format=png&auto=webp&s=785aabb1c9546688945f4a3c41a0aac487d19637
Plastic deformation of final forging dies https://preview.redd.it/f80ejik9086h1.png?width=1137&format=png&auto=webp&s=5e1a78a091018386469c9112452dd4d70144c7b2
Task https://preview.redd.it/m1jez14d086h1.png?width=590&format=png&auto=webp&s=2b133f160159553411994c03a00bd378c6f624b7
#industry
source
Hi everyone,
I'm currently working on my diploma thesis, which focuses on the determination and simulation of the forging process for a specific component (shown in the attached images). The task also specifies minimization of forging steps and also some temperature limitations are presented.
I've already run about 100 simulations, but I am completely stuck trying to find the right preform geometry. I have tried multiple approaches and optimization algorithms, including the electrostatic field method and simple moving averages, but nothing seems to give a successful result.
I keep running into two major issues:
1. Material Flow Defects: I am experiencing severe issues with Gartfield field parameter.
2. Extreme Forming Forces: The required tonnage/force is incredibly high, which ultimately results in the plastic deformation of the tooling/die—which is, of course, unacceptable.
Also literature specifically dedicated to forging preform determination and optimization methods seems to be very limited.
I would deeply appreciate any advice or insight:
* Has anyone encountered a similar issue where the preform design causes either severe defects or tool-deforming forces?
* Can anyone recommend good literature, textbooks, or research papers focusing on preform design which will literarly guide me through the whole process of designing it (I just can´t find any)?
* Are there alternative simulation strategies or geometric approach rules I might have overlooked?
I am using QForm UK software.
**Please help me I am completely lost and I have already lost 1 month with preform design, it seems like nothing works for me. I am seeking for any kind of advice and I truly need help. Thanks in advance.**
If anyone would like to see more content about the problem I will kindly send it.
Shape of preform with Gartfield field https://preview.redd.it/vo1f6zi0086h1.png?width=1055&format=png&auto=webp&s=43e8b5c941fd5fde7ed6305e10d5b66ad6fcbc22
Shape of final forging with Gartfield field https://preview.redd.it/vhk6v6s6086h1.png?width=1016&format=png&auto=webp&s=785aabb1c9546688945f4a3c41a0aac487d19637
Plastic deformation of final forging dies https://preview.redd.it/f80ejik9086h1.png?width=1137&format=png&auto=webp&s=5e1a78a091018386469c9112452dd4d70144c7b2
Task https://preview.redd.it/m1jez14d086h1.png?width=590&format=png&auto=webp&s=2b133f160159553411994c03a00bd378c6f624b7
#industry
source
| 2,000 mlx | |
| 3 | |
| 0 |