A new approach of preform design based on 3D electrostatic field simulation and geometric transformation

Preform design is an important aspect of the research and development of the forging processes, which plays a key role in improving product quality, such as improving material filling capacity and reducing forming loads. In industry, preforms are generally designed by the iterative trial-and-error approach. This approach, however, leads not only to the increase of tool cost but also to prolonged production time. On the basis of the minimum energy principle and the minimum resistance law, a new approach by means of 3D electrostatic field simulation and geometric transformation is proposed in this paper to design the preform shape. Two axisymmetric (a disk and a blind-hole) forgings and a long-axis part are used to demonstrate this method, and finite element package DEFORM 3D is used to simulate the forming process for the purpose of verifying the validity and effectiveness of this approach.