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

在本研究中，将开发一种新的难锻件预成形模具形状和工艺条件集成设计方案。工业界提供的设计目标和性能要求将被用于制定模具形状设计程序。其新颖之处在于将多目标模具形状演化和过程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和场变量的关系、有限元建模和形状优化方法。将工件的变形能、应变率变化和温度分布作为多目标来控制高温材料的加工。该方法通过在变形的关键步骤采用自动化工艺参数设计，考虑了材料的非线性行为和不断变化的边值问题。优化后的设计将在两个工业基地进行实验验证，一个代表航空航天，另一个代表重型机械部件。作为两个合作行业的结果，材料选择将包括“异国情调”的钛铝化物以及“高容量”钢。这一研究的成功证明有望对锻造的成本和质量产生积极的影响，特别是对于复杂的设计和难以加工的材料。在工业合作伙伴的制造“拉动”下，研究成果可能会迅速得到实施。＊＊＊

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. ***