Preform Shape Optimization of Connecting Rod Using Finite Element Method and Taguchi Method

Preform design in forging processes is an important aspect for improving the forging quality and decreasing the production cost. The objective of this paper is to obtain an optimal perform shape in the consideration of the influence of the metal flow deformation in closed die forging process. Finite element method based DEFORMTM 3D software in conjunction with Taguchi method has been used to simulate the closed die forging process and then performing a series of optimization iterations in order to obtain the optimal shape of the billet based on forging load minimization. The goal of the simulation and optimization process is to minimize the forging load and produce defect-free forgings. The optimal shape of the billet that gives minimum forging load with complete die filling was obtained after several optimization iterations. The approach used in this study could be extended to the optimization of more complicated forging products.