Optimization and design of multistage hot forging processes by numerical simulation and experimental verification

Abstract

Multi stage hot forging processes make possible to produce variety of components with different shape, size and different materials. In these processes it is essential to design forging steps in optimal way. In previous times set-up of forging steps in multi stage processes was mainly conducted based upon experience gained in the forging practice. Nowadays, software packages based on FE (finite elements) and FV (finite volumes) method, are developed which enable creation of forging process optimization in more effective and more reliable way. In this paper insight is given in the optimization of hot forging of wheel hub as well as in the design of the multi-step forging process of joint socket. Optimization criteria were minimal number of forging stages, die filling and stressing of the top and bottom die by contact pressures. Simulation and optimization results are verified in practical, industrial environment.