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Compensation of billet variabilities through metamodel-based optimization in open die forging

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Abstract

Closed-die forging preforms are usually made by open die forging operations, which are subject to significant variabilities. A sensitivity study covering a wide range of influencing parameters has highlighted the predominant influence of the initial billet geometry. The forging die strokes were also highly influential, while their fidelity is sufficient to use them as control parameters in order to compensate the geometrical dispersions of the billet. Consequently, their optimization was performed by taking a nominal preform geometry as the target. Polynomial surrogate models have been constructed to enable real-time optimization. A specific preform was used as a demonstrator in this study, while the approach was generic. The surrogate models were built using data from finite element simulations, which were first validated with an experimental campaign. On the one hand, this approach introduced agility by allowing changes in the billet geometry, and on the other hand, it allowed individual customization of the specific route to each billet.

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Data Availability

The data are not available.

Code availability

The finite element simulations were performed with the FORGE.NxT\(\copyright \) commercial Software. No code was specifically developed to obtain the results presented in the article.

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Acknowledgements

The authors are grateful to Stéphane Beinstingel and Olivier Gyss from Setforge Bouzonville for their technical contribution. The financial support from the Région Grand Est (France) and the FEDER - fond européen de développement régional - through the SAFIRE project is gratefully acknowledged.

Funding

This work was supported by the REGION GRAND-EST and the European Regional Development Fund.

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Authors and Affiliations

  1. Arts et Metiers Institute of Technology, Université de Lorraine, LCFC, HESAM Université, Metz, F-57070, France

    Simon Fays, Cyrille Baudouin, Laurent Langlois, Tudor Balan & Régis Bigot

  2. Research and Development Department, Setforge Bouzonville, Bouzonville, F-57320, France

    Marc Borsenberger

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  1. Simon Fays
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  2. Cyrille Baudouin
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  3. Laurent Langlois
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  4. Marc Borsenberger
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  5. Tudor Balan
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Correspondence to Laurent Langlois.

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Fays, S., Baudouin, C., Langlois, L. et al. Compensation of billet variabilities through metamodel-based optimization in open die forging. Int J Adv Manuf Technol 132, 1665–1678 (2024). https://doi.org/10.1007/s00170-024-13392-3

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