Preform Optimization of Functional Bevel Gear for Warm Forging Processes

Febriani, Risky Ayu; Park, Hong Seok; Kumar, Saurabh; Lee, Chang-Myung

doi:10.1007/s12239-020-0103-y

Cited by 3 publications

(1 citation statement)

References 8 publications

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“…In addition, it is possible to use other physical fields to describe the material flow and thus obtain the shape of the preform, for example, by integrating QForm metal forming simulation software with special CAD software that enables isothermal surface extraction to preform modeling [27]. With the development of random computer technology, a preform shape design method based on optimal design is widely used, which is to optimize the design variables related to the preform shape size to get the optimal solution with a particular index or a specific relative relationship as the objective function, such as response surface method (RSM) [29][30][31], sensitivity analysis [32,33], genetic algorithms (GA) [34][35][36], topological optimization [37,38] and reduced basis technique (RBT) [39].…”

Section: Introductionmentioning

confidence: 99%

Automatic preform design and optimization for aeroengine disk forgings

Han

Wang

Chen

et al. 2023

Int J Adv Manuf Technol

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To ensure a more uniform microstructure distribution of forging and improve the service performance of aeroengine disk parts, an automated preform design method is proposed for integrated preform shape design and optimization based on the NURBS curve, finite element method (FEM), and genetic algorithm (GA). Firstly, the random preform shape graph is automatically constructed by the NURBS curve design criterion. The volume and shape complexity are used as the constraints of the preform. Then the ratio of the mesh area within the set strain range to the total mesh area is used as the fitness function for the uniformity of deformation, and the genetic algorithm module is used for optimization. Finally, a large disk forging is an example of its optimal design. The results show that the deformation uniformity of the forgings is excellent, its fitness value is as high as 99.59%, and there are no problems such as folding, underfilling, and limited distribution of flash, which verifies the effectiveness of the method. In addition, the method has the advantage of strong universality, which can find the preform shape with good deformation uniformity for any shape forgings.

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Section: Introductionmentioning

confidence: 99%

Automatic preform design and optimization for aeroengine disk forgings

Han

Wang

Chen

et al. 2023

Int J Adv Manuf Technol

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Analysis and optimal design of forging preforming for I-shaped forgings

Huang,

Zhong

2024

J. Phys.: Conf. Ser.

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The optimal design of forging preforming is the key to improving forging quality and productivity. Taking an I-shaped forging as a research object, an approach to optimize two-dimensional preform shape is employed. The mathematical model of multi-objective optimization in forging forming simulation is established, and the forming load and die wear are used as the objective functions to optimize the design. Two forms of straight line and circular arc are designed for the shape of the deformation area of the preforming die. With the aid of the finite element simulation software, the process of preforming and finishing forging by using the preformed die with different design variables and different parameters is simulated. Simulation results show that the best optimization results can be achieved when the linear angle is 53.5° and the circular arc radius is 66 mm. After optimization, the load drops by about 36 percent by adopting the circular arc shape, and by about 76 percent by adopting the straight-line shape. The die wear depth decreases and the wear zones become more balanced after optimization. Numerical results prove that this approach is effective in designing the optimal preform shape in forging.

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Forging weight Reduction of gear blank by Topology Optimization using Parametric FEA

Mehta

Kuthiya

Hadiya

et al. 2022

Preprint

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In any gearbox, gears play a crucial role in motion transmission and contribute considerable weight to the gearbox. Usually, gears fail when the operating stress exceeds the maximum permissible stress. The power transmitted by the gears is directly proportional to these stresses. This paper intends a systematic study of gear blank hub, web, and rim geometry along with rim angle and fillets to reduce the weight of helical gear without altering the material and tooth geometry with the proper balance between weight reduction and total deformation. In turn, the total deformation in optimized gear will be in the safety range, 30% of existing gear deformation. Also aims to determine the magnitude of total deformation and Von-Mises stresses for a particular configuration of helical gears that transfer power while maintaining functionality and lowering the gear's material cost and energy consumption. Incorporating change in dimensional features of gear blank for weight reduction over the existing design and evaluation of individual feature behavior trends could be considered as the key parameters for assessment for this work.

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Preform Optimization of Functional Bevel Gear for Warm Forging Processes

Cited by 3 publications

References 8 publications

Automatic preform design and optimization for aeroengine disk forgings

Automatic preform design and optimization for aeroengine disk forgings

Analysis and optimal design of forging preforming for I-shaped forgings

Forging weight Reduction of gear blank by Topology Optimization using Parametric FEA

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