Forging parameter optimization considering stress distributions in products through FEM analysis and robust design methodology

Residual stress distribution forgings directly affect material stability, resistance to deformation, accuracy, and the fatigue life of products. In order to extend the operating life of products and satisfy the quality of operation during the customer usage, it is necessary to monitor residual stresses during the forging operations. The finite element method and robust design methodology were utilized to identify the controlling process parameters which can monitor the residual stresses in forged products. In the optimizing process of the forging operation, experimental planning was performed by using the orthogonal array and concept of the signal-to-noise ratio. Frictional coefficient, length of die land, reduction percentage, inlet angle and comer fillet were selected as process parameters. The ANOVA analysis showed that the inlet angle, friction coefficient and length of die land have the most significant effects on the optimum residual stresses.