Optimum design of forging dies using the finite element method

In this paper, a die design method is presented for multistage forging of engineering components. Backward deformation analysis is used to reverse the deformation process and determine an optimum intermediate die shape. In the backward deformation method, the final component shape is taken as the starting point, and the die is moved in the reverse direction with boundary nodes being released as the die is raised. A boundary node releasing decision making strategy based on fuzzy logic is used to define the boundary condition in each backward time increment. To specify the die wear tolerance, the total friction work of the die surface is calculated and appropriate die dimensions determined. 1