Optimization of energy distribution in hydraulic hammer forging considering billet jumping based on the three actuals

Abstract

This paper presents an optimization of energy distribution in hydraulic hammer forging based on the three actuals which are (1) actual place, (2) actual product and (3) actual situation. For the automation in the hydraulic hammer forging, “billet jumping” during the forging process is a fatal defect. It is much difficult to simulate the billet jumping through numerical simulation. Thus, it is important to determine the optimal energy distribution without using numerical simulation. To successfully determine the optimal energy distribution in hydraulic hammer forging, first, several experiments based on the latin hypercube design sampling are conducted. Then, multi-objective optimization minimizing total energy and billet thickness is performed. In this process, the billet jumping is numerically evaluated through the experiments and is handled as the design constraint. Surrogate-based optimization using radial basis function network is performed to determine the optimal energy distribution considering the billet jumping. Through the experimental result, the hydraulic hammer forging using the optimal energy distribution is successfully conducted without the billet jumping.