In the actual forging production, when the geometrical shape of the forging is complex or the traditional design method has limitations, the unreasonable forging process and mold design may make the internal structure, appearance shape or surface quality of the forging unable to meet the specified technical requirements. Even serious forming defects such as filling defects, surface folds, internal or surface cracks, etc. may occur. In addition, unreasonable designs can also lead to serious material waste and low mold life.
With the increasing competition, low-cost, high-quality and high-efficiency are the goals pursued by the manufacturing industry. In order to reduce manufacturing costs and improve product quality, it is necessary to optimize various process parameters that affect the quality of the forging during the forging process. The forging process involves complex geometric and physical changes, and it is difficult to achieve the desired results using traditional design optimization methods, and only the comparison of design schemes and the continuous improvement of a certain process can not be separated from physical experiments. With the continuous development and consummation of modern computer technology and plastic finite element theory, the numerical simulation method based on the finite element method has been successfully applied to the numerical simulation of deformation laws and multiphysics of forgings in the plastic forming process. Mold design provides reliable virtual verification. Therefore, the application of design optimization based on numerical simulation in forging process and mold design is not only possible but also inevitable.