In this study, three parameter optimization methods and two designs of experiments (DOE) were used for the optimization of three major design parameters ((bill diameter (D), billet length (L), and barrier wall design (BWD)) in crown forging to improve the formability of aluminum workpiece for shock absorbers. The first optimization method is the response surface method (RSM) combined with Box–Behnken’s experimental design to establish fifteen (15) sets of parameter combinations for research. The second one is the main effects plot method (MEP). The third one is the multiobjective optimization method combined with Taguchi’s experimental design method, which designed nine (9) parameter combinations and conducted research and analysis through grey relational analysis (GRA). Initially, a new type of forging die and billet in the controlled deformation zone (CDZ) was established by CAD (computer-aided design) modeling and the finite element method (FEM) for model simulation. Then, this investigation showed that the optimal parameter conditions obtained by these three optimization approaches (RSM, MEP, and multiobjective optimization) are consistent, with the same results. The best optimization parameters are the dimension of the billet ((D: 40 mm, the length of the billet (L): 205 mm, and the design of the barrier wall (BWD): 22 mm)). The results indicate that the optimization methods used in this research all have a high degree of accuracy. According to the research results of grey relational analysis (GRA), the size of the barrier wall design (BWD) in the controllable deformation zone (CDZ) has the greatest influence on the improvement of the preforming die, indicating that it is an important factor to increase the filling rate of aluminum crown forgings. At the end, the optimized parameters are verified by FEM simulation analysis and actual production validation as well as grain streamline distribution, processing map, and microstructure analysis on crown forgings. The novelty of this work is that it provides a novel preforming die through the mutual verification of different optimization methods to solve a typical problem such as material underfill.
In this research, numerical analysis, response surface method (RSM) and experiments are used to investigate and verify the hot forging process for manufacturing aluminum crown forgings for shock absorber assembly. First, establish the computer aided design (CAD) model of the die and the billet, and simulate it from the finite element method (FEM). Second, a new preforming die was designed with a preformed dressing of controllable deformation zone (CDZ) by the CAD software. Third, numerical simulation was combined with RSM to optimize the processing parameters with the aim of minimizing the die wear while the integrity of forgings should be prioritized preserved. According to RSM, the billet size and preformed dressing of CDZ are important factors affecting the distance between die and workpiece (C). The optimal design factor of the preforming die: billet diameter (D), billet length (L) and flash design (F) are 40 mm, 205 mm and CDZ 1, respectively. Through the results of FEM, this study describes the distribution of microscopic grain flow lines are highly related to forming, stress, strain, and temperature as well as die design such as CDZ in preformed dressing. In order to accurately verify that the parameters analyzed by the RSM, both numerical analysis and physical experiments are carried out and optimal scheme exhibit reasonable consistency.
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