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Preform optimization for hot forging processes using an adaptive amount of flash based on the cross section shape complexity

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Abstract

In multistage hot forging processes, the preform shape is the parameter mainly influencing the final forging result. Nevertheless, the design of multistage hot forging processes is still a trial and error process and therefore time consuming. The quality of developed forging sequences strongly depends on the engineer’s experience. To overcome these obstacles this paper presents an algorithm for solving the multi-objective optimization problem in designing preforms. Cross wedge rolled preforms were chosen as subject of investigation. An evolutionary algorithm is introduced to optimize the preform shape taking into account the mass distribution of the final part, the preform volume and the shape complexity. A crucial factor in preform optimization for hot forging processes is the amount of flash. Therefore an equation for improving the amount of flash is derived. The developed algorithm is tested using two connecting rods with different shape complexities as demonstration parts.

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Acknowledgments

The authors thank the German Research Foundation (Deutsche Forschungsgemeinschaft) for the funding of the research project “Entwurf optimaler Vorformstufen zum Herstellen von Schmiedebauteilen unter Anwendung von stochastischen Optimierungsverfahren” (DFG Be 1691/177-1 and DFG OV 36/22-1). The authors thank the Hammerwerk Fridingen GmbH for the support in this project.

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  1. Institut für Integrierte Produktion Hannover, Hollerithallee 6, 30419, Hannover, Germany

    Johannes Knust, Malte Stonis & Bernd-Arno Behrens

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  1. Johannes Knust
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  2. Malte Stonis
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  3. Bernd-Arno Behrens
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Correspondence to Johannes Knust.

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Knust, J., Stonis, M. & Behrens, BA. Preform optimization for hot forging processes using an adaptive amount of flash based on the cross section shape complexity. Prod. Eng. Res. Devel. 10, 587–598 (2016). https://doi.org/10.1007/s11740-016-0702-7

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