DESIGN OF FORGING PROCESS PARAMETERS WITH DEFORMATION AND TEMPERATURECONSTRAINTS

This paper presents a methodology for designing optimal process parame ters for forging operations. The nonlinear rigid viscoplastic finite e lement (FE) method is used for deformation and thermal analyses. From the FE model a state space system is developed for representing the co upled deformation and thermal behavior of the metal forming system. Co nstraints are imposed on the strain rate and temperature of the deform ing workpiece for obtaining the desired physical/microstructural prope rties in the final product. The linear quadratic regulator (LQR) theor y for finite time control is used in designing the initial die tempera ture and optimal ram velocity schedules. The approach is demonstrated on a plane strain channel section forging under nonisothermal conditio ns.