GOALI/IUCRP: A Multi-Objective Design System for Forging Difficult-to-Process Materials

9424649在这项研究中，将开发一种新的方案，用于难以锻造的部件的预制件模具形状和工艺条件的集成设计。在制定模具形状设计程序时，将考虑行业提供的设计目标和性能要求。其新颖之处在于将多目标模具形状演变和工艺控制设计优化程序与粘塑性有限元分析相结合。该设计方案利用了微观结构与场变量的关系、有限元建模和形状优化方法。以变形能、应变速率变化量和温度分布为多目标，对高温材料的加工进行控制。该方法通过在变形的关键步骤使用自动工艺参数设计，考虑了材料的非线性行为和不断变化的边值问题。优化设计将在两个工业现场进行实验验证，一个代表航空航天，另一个代表重型机械部件。作为两个行业合作的结果，材料选择将包括“奇异的”钛铝化物以及“大批量”钢。这项研究的成功示范预计将在锻造成本和质量方面产生积极影响，特别是对于复杂的设计和难以加工的材料。在制造业合作伙伴的拉动下，研究成果很可能会迅速实施。***

9424649 Grandhi In this research, a novel scheme for integrated design of preform die shapes and process conditions for difficult-to-forge components will be developed. Industry provided design goals and performance requirements will be taken in formulating the die shape design procedures. The novelty lies in the combined use of multi-objective die shape evolution and process control design optimization procedures along with viscoplastic finite element analysis. The design scheme makes use of the relationships of microstructure and field variables, finite element modeling, and shape optimization approaches. The deformation energy, variance of strain-rate and temperature distributions in the workpiece are used as multiple-objectives to control the processing of high temperature materials. This approach takes into account the nonlinear material behavior and a constantly changing boundary value problem by using an automated process parameter design at critical steps of deformation. The optimized designs will be experimentally validated at two industrial sites, one representing aerospace and the other heavy machinery parts. As a result of two collaborating industries, material selection will include "exotic" titanium aluminide as well as "high volume" steel. Successful demonstration of this research is expected to have a positive impact in terms of cost and quality of forging, especially for intricate designs and hard to process materials. With a manufacturing "pull" from the industrial partners, the research results are likely to be implemented rapidly. ***