This project is a continuation of the prior project on Process Design in Metal Forming. A goal of research in manufacturing is to accomplish proper design and control of processes for producing required parts most economically. One of the most important aspects of process design in metal forming is design of preforms and process sequence. In the prior project, the application of the new approach to preform design in complex forming processes has been investigated. The approach used capability of forward simulation and backward tracing of a forming process by the finite element method. Significant accomplishments were the development of the finite element method and implementation of the backward tracing procedure for three dimensional deformation processes. The results of these investigations demonstrate that it is possible to design preforms without resort to designer's experience. In the prior project, the design criterion considered was a geometrical requirement for the final product. For process sequence design, additional requirements must be introduced in the design process. Thus, the objective of the research is to develop the methodology for systematic process sequence design, considering quantitatively requirements for material formability, defects-free metal flow and economic die manufacturing, in addition to the geometrical requirement. Many industrial parts are formed sequentially by multiple dies, each of which contributes to the final shape change. The project will provide analytical tools for designing the required dies, which are now designed by trial and error, based on experience.
