Abstract
An optimal multi-stage cold forging process is one that allows for the most product throughput for an acceptable batch size while limiting the cost associated with producing quality parts. The goal of this research was to address this issue and start to establish a basis that manufacturing engineers can use when they design the progression of any multi-stage forging operation. The research methodology employed utilized basic forging science principles applied in the form of a numerical forging simulator. The usage of this simulator was coupled with a customized optimization sequence to iteratively determine the most effective multi-stage forging sequence for selected classes of products. As a result of this research endeavor, it was shown that this comprehensive science-based optimization approach can lead to the significant enhancement of multi-stage forging processes.
