Optimizing the shape of the initial billet in the forging of complex rotational parts through the reduced basis method

In this study, the reduced basis method (RBM) was used to find the optimum shape of the initial billet in cold forging of rotational axisymmetric parts. The main goal is to simultaneously optimize the appropriate initial billet shape with lower forging force. First, a finite element (FE) model of the process was developed using ABAQUS software and then the model was verified through experimental tests. The obtained data from the FE simulation has been integrated with the RBM to find the weight factors of billet shapes. Furthermore, the optimal results were checked by both numerical and experimental approaches. Results indicated that the optimum shape of the initial billet obtained by the RBM significantly decreases the forging force. A decrease of 6% was obtained in the optimum billet shape compared to the best-defined billet shape. Also, the optimum shape leads to a better die filling.