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

小行星9424649 本研究将针对难锻零件之预成形模具形状与工艺条件之整合设计，提出一种新的方案。 工业提供的设计目标和性能要求将在制定模具形状设计程序。 新颖之处在于结合使用多目标模具形状演变和工艺控制设计优化程序沿着粘塑性有限元分析。 该设计方案利用微观结构和场变量的关系，有限元建模和形状优化方法。 采用变形能、应变率方差和工件温度分布作为多目标控制高温材料的加工。 这种方法考虑到非线性材料的行为和不断变化的边界值问题，通过在变形的关键步骤使用自动化的工艺参数设计。 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。 由于两个行业的合作，材料的选择将包括“异国情调”的钛铝化物以及“高容量”的钢。 这项研究的成功演示预计将对锻造的成本和质量产生积极影响，特别是对于复杂的设计和难以加工的材料。 在工业伙伴的制造“拉动”下，研究成果很可能迅速得到实施。 ***

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. ***