Optimization Support Method for Cold and Warm Forging Dies of Non-axisymmetrical Forged Products

The general step reduction and enlargement (GeneSteR + E) method and the general forging die design (GeneDie) method can exhaustively generate forging processes and dies for non-axisymmetric forged products. However, the variation of generated plans are limited, potentially excluding optimal solutions. This paper proposes an optimization support method that generates alternative design plans for non-axisymmetric forged products. The proposed method generates various die design plans according to various shapes of a workpiece and relative positions of the forged product and workpiece to dies. The shape of an initial work material is generated by resizing the shape in an original process plan while keeping the same volume as planned, and the parting lines of dies are defined by rotating the forged product around its center of gravity. The positions of the workpiece are generated by distributing the workpiece around its center of gravity. The shape of a forged product is modified so that undercut constraints are satisfied on the premise of subsequent blanking or punching processes. A large number of design candidates are evaluated by a finite element method analysis tool using a robotic process automation (RPA) tool. An experimental design knowledge base and RPA workflows were developed and applied to the forging dies of automotive parts. The experimental results show that the proposed method can generate alternative forging dies including those nearly equivalent those designed by an experienced engineer but in less time.