Skip to main content
SpringerLink
Log in

Sensitivity analysis based preform die shape design using the finite element method

  • Processing
  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

This paper uses a finite element-based sensitivity analysis method to design the preform die shape for metal forming processes. The sensitivity analysis was developed using the rigid visco-plastic finite element method. The preform die shapes are represented by cubic B-spline curves. The control points or coefficients of the B-spline are used as the design variables. The optimization problem is to minimize the difference between the realized and the desired final forging shapes. The sensitivity analysis includes the sensitivities of the objective function, nodal coordinates, and nodal velocities with respect to the design variables. The remeshing procedure and the interpolation/transfer of the history/dependent parameters are considered. An adjustment of the volume loss resulting from the finite element analysis is used to make the workpiece volume consistent in each optimization iteration and improve the optimization convergence. In addition, a technique for dealing with fold-over defects during the forming simulation is employed in order to continue the optimization procedures of the preform die shape design. The method developed in this paper is used to design the preform die shape for both plane strain and axisymmetric deformations with shaped cavities. The analysis shows that satisfactory final forging shapes are obtained using the optimized preform die shapes.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. S. Kobayashi, S.I. Oh, and T. Altan, Metal Forming and the Finite Element Method, Oxford University Press, 1989

  2. N. Kim and S. Kobayashi, Preform Design in H-Shaped Cross Section Axisymmetric Forging by Finite Element Method, Int. J. Mach. Tools Manuf., Vol 31,1991, p 243–268

    Google Scholar 

  3. B.S. Kang, N. Kim, and S. Kobayashi, Computer-Aided Preform Design in Forging of an Airfoil Section Blade, Int. J. Mach. Tools Manuf., Vol 30, 1990, p 43–52

    Article  Google Scholar 

  4. B.S. Kang and S. Kobayashi, Preform Design in Rolling Processes by the Three Dimensional Finite Element Method, Int. J. Mach. Tools Manuf., Vol 31, 1991, p 139–151

    Article  Google Scholar 

  5. G. Zhao, E. Wright, and R.V. Grandhi, Preform Design in Forging Processes Using Nonlinear Finite Element Method, Trans. NAMRI/SME, Vol 22, 1994, p 17–24

    Google Scholar 

  6. G. Zhao, E. Wright, and R.V. Grandhi, Forging Preform Design with Shape Complexity Control in Simulating Backward Deformation,0 Int. J. Mach. Tools Manuf, Vol 35, 1995, p 1225–1239

    Article  Google Scholar 

  7. G. Zhao, E. Wright, and R.V. Grandhi, Computer Aided Preform Design in Forging Using the Inverse Die Contact Tracking Method, Int. J. Mach. Tools Manuf, Vol 36, 1996, p 755–769

    Article  Google Scholar 

  8. S. Badrinarayanan and N. Zabaras, A Sensitivity Analysis for the Design of Metal Forming Processes, Comput. Meth. Appl. Mech. Eng., Vol 129, 1996, p 319–348

    Article  Google Scholar 

  9. L. Fourment, T. Balan, and J.L. Chenot, Shape Optimal Design in Forging,NUMIFORM’95, S.F. Shen and P.R. Dawson, Ed., A.A. Balkema/Rotterdam/Brookfield, 1995, p 557–562

  10. G. Zhao, E. Wright, and R.V. Grandhi, Preform Die Shape Design in Metal Forming Using an Optimization Method, Int. J. Numer. Methods Eng., (in press), 1997

  11. G. Zhao, E. Wright, and R.V. Grandhi, Sensitivity Analysis Based Preform Die Shape Design for Net-Shape Forging, Int. J. Mach. Tools Manuf, (in press), 1997

  12. R. Fletcher, Practical Methods of Optimization, John Wiley and Sons, Inc., 1987

  13. Vanderplaats Research & Development, Inc., DOT Users Manual, Version 4.20, Colorado Springs, CO, 1995

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Materials Engineering, Shandong University of Technology, 250061, Jinan, Shandong, China

    G. Q. Zhao

  2. Department of Mechanical and Material Engineering, Wright State University, 45435, Dayton, OH, USA

    R. Hufi, A. Hutter & R. V. Grandhi

Authors
  1. G. Q. Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. R. Hufi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. A. Hutter
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. R. V. Grandhi
    View author publications

    You can also search for this author in PubMed Google Scholar

Rights and permissions

Reprints and permissions

About this article

Cite this article

Zhao, G.Q., Hufi, R., Hutter, A. et al. Sensitivity analysis based preform die shape design using the finite element method. J. of Materi Eng and Perform 6, 303–310 (1997). https://doi.org/10.1007/s11665-997-0094-0

Download citation

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-997-0094-0

Keywords

Search

Navigation