Multi-objective optimization of cavity design for GH4738 superalloy profile ring rolling process based on FEM and RSM

During the rolling process of profile ring, the design of the rolling cavity directly affects the forming quality of the final ring and the production cost of the rolling process. To improve the cavity filling rate and reduce the production cost, the response surface method (RSM) is combined with a verified three-dimensional thermodynamic coupled finite element model to optimize the design of the rolling cavity for the profile ring rolling process. Firstly, a universally applicable design method for profile ring rolling cavity is proposed, and based on the description of the rolling cavity, three design variables and two corresponding response objectives are defined to achieve multi-objective optimization. Secondly, a verified finite element model is established to simulate the rolling process. Based on the simulation results, a response model is developed and modified by significance analysis and analysis of variance (ANOVA). Then through this response model, the effects of different variables on the optimization objectives are studied comprehensively. Finally, the optimal rolling cavity size is determined by combining the response optimization diagram, and the effectiveness of the optimization method is verified by forming experiments.