Skip to main content
SpringerLink
Log in

Optimization design preform billet shape of 7050 aluminum alloy giant plane forgings based on electric field method and MBC toolbox

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The preform billet shape of the 7050 aluminum alloy giant plane forgings has been designed using electric field method based on similarity principle. Firstly, the electrostatic field was analysed by using ANSYS software, from which the preform billet shape was obtained based on electrostatic field equipotential lines. The preform shape, press velocity, temperature and friction factor were taken as parameter variables, while the forming load, filling rate and grain size were chosen as optimization goals. The mathematical model was optimized by the use of a Model-Based Calibration (MBC) toolbox for modelling, Three-Dimensional of Design Environment for FORMing (DEFORM-3D) for simulation and CAlibration GEneration (CAGE) toolbox, obtaining the best preform shape and the optimal combination of process parameters (friction factor μ = 0.2, press velocity ν = 9.8 mm/s and billet temperature T = 478 °C) when the equipotential line was ξ = 0.425 V. Finally, comparing with initial preform shape, the results indicate that the optimized preform billet designed by electric field method has an advantage in finish forging, while the forming load of finish forging reduces by about 38 % and the average micrograin size reduces by about 45 %. Therefore, it provides an effective method for designing preform billet shape of complex forgings.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Zhao XH, Zhao GQ, Wang GH (2000) The current situation and development of preform design in bulk metal forming. J Plast Eng 7(3):1–6

    Google Scholar 

  2. Pack JJ, Rebelo N, Kobayshi S (1983) A new approach to preform design in metal forming with the finite element method. Int J Mach Tool Des Res 23(1):71–79

    Article  Google Scholar 

  3. Tang YC, Zhou XH, Chen J (2008) Preform tool shape optimization and redesign based on neural network response surface method-ology. Finite Elem Anal Des 44(8):462–471

    Article  Google Scholar 

  4. Ma XW, Zhao XH, Zhao GQ, Wang GC (1999) Optimal preform die shapes design using sensitivity analysis based finite element method. Mater Sci Technol 7:96–99

    Google Scholar 

  5. Sedighi M, Tokmechi S (2008) A new approach to preform design in forging process of complex parts. J Mater Process Technol 197(1/3):314–324

    Article  Google Scholar 

  6. Lee SR, Lee YK, Park CH, Yang DY (2002) A new method of preform design in hot forging by using electric field theory. Int J Mech Sci 44(4):773–792

    Article  MATH  Google Scholar 

  7. Zhang RP, Li FG, Xiao J (2007) Isothermal forging pre-forming design of PM super alloy disc based on equipotential field. Hot Work Technol 36(9):70–74

    Google Scholar 

  8. Li C (2005) Study on similar equipotential - field simulation method in materials processing engineering. Northwestern Polytechnical University, Master’s Thesis, pp 13–17

  9. Xiao J, Li FG (2006) Equipotential field simulation for the gas pressure superplastic bulging of axisymmetrical circular sheets. J Plast Eng 13(2):14–19

    MathSciNet  Google Scholar 

  10. Ko DC, Kim DH, Kim BM, Choi JC (1998) Methodology of preform design considering workability in metal forming by the artificial neural network and Taguchi method. J Mater Process Technol 80–81:487–492

    Article  Google Scholar 

  11. Poursina M, Arvizian J, Antonio C (2006) Optimum pre-form dies in two-stage forging. J Mater Process Technol 174(1/3):325–333

    Article  Google Scholar 

  12. Özdemir M, Ergin AA (2006) Rotations with unit time like quatemions in Minkowski 3-space. J Geom Phys 56(2):322–336

    Article  MATH  MathSciNet  Google Scholar 

  13. Zhang Q, Hu RX, Kang ST (2010) Electromagnetic finite element analysis from entry to the master of ANSYSl2.0 (in Chinese). Beijing Mechanical Industry Press

  14. Xie HG, Xu L, Wang H, Jiang SM, Fang LF, Tang J (2008) The research of three 3D reconstruction methods of Mimics V10. 0 software. Med J West China 20(5):1089–1091

    Google Scholar 

  15. Zhao XH, Zhao GQ, Wang GC, Wang TH (2002) Research on the shape optimization of billet in metal forging process. Forging Stamping Technol 27(02):3–5

    Google Scholar 

  16. Rong QE, Cheng CW (2002) Latin hyper cube sampling in ultimate strength reliability of ship hull grider. J Ship Mech 3:52–57

    Google Scholar 

  17. Jie Z, Lei L, Yan L (2014) The multi-objective optimization design of a new closed extrusion forging technology for a steering knuckle with long rod and fork. Int J Adv Manuf Technol 72:1219–1225

    Article  Google Scholar 

  18. Jie Z, Yu YY, Zeng Q (2014) Analysis and experimental studies of internal voids in multi-wedge cross wedge rolling stepped shaft. Int J Adv Manuf Technol 72:1559–1566

    Article  Google Scholar 

  19. Ho T, Karri V (2011) Hydrogen powered car: two-stage modeling system. Int J Hydrog Energy 36:10065–10079

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. College of Materials Science and engineering, Chongqing University, Chongqing, 400044, China

    Yaping Tao, Jie Zhou, Jindou Cao, Yan Luo & Banghua Chen

Authors
  1. Yaping Tao
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jie Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jindou Cao
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yan Luo
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Banghua Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yaping Tao.

Additional information

Foundation item: Natural Science Foundation of China (no. 51275543) and major special projects of Chinese Ministry of Science & Technology (no. 2012ZX04010-081)

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Tao, Y., Zhou, J., Cao, J. et al. Optimization design preform billet shape of 7050 aluminum alloy giant plane forgings based on electric field method and MBC toolbox. Int J Adv Manuf Technol 81, 231–240 (2015). https://doi.org/10.1007/s00170-015-7149-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-015-7149-4

Keywords

Search

Navigation