Model Based Optimization of Forging Process Chains by the Use of a Genetic Algorithm.

In this paper, a new approach for a holistic process chain optimization of forged components based on generic process models is presented. Interdependencies between single processes and the process chains of the forged component production and the forging die manufacturing have been analysed mathematically, emulated and integrated in the corresponding process models. Based on this preliminary work, an optimization of process parameters by the use of a Genetic Algorithm was integrated in a software prototype. The paper ends with a comparison and discussion of the results from the generic model based optimization method by the use of a Genetic Algorithm and the Finite Element simulation. It is shown that the holistic generic model based optimization method provides results that allow a production of forged components with optimized process parameters deviant from typical process parameters to lower production costs.