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Zhu F.,Wuhan University of Science and Technology | Wang Z.,Wuhan University of Science and Technology | Lv M.,Chongqing Construction Industrial group CO.
International Journal of Advanced Manufacturing Technology | Year: 2015

To control the precision forging product forming quality, a multi-objective optimization method for process parameters design was proposed by applying Latin hypercube design method and response surface model approach. Meanwhile, the deformation homogeneity and material damage of forging product was first presented for evaluating the forming quality. Then, as a case of study, the radial precision forging for a hollow shaft with variable cross section and wall thickness was carried out. The 3D rigid-plastic finite element (FE) model of the radial precision forging was established. The parameters on the forming quality evaluation function study were discussed to investigate the multi-objective optimization model. Non-dominated sorting genetic algorithm-II (NSGA-II) was adopted to obtain the Pareto-optimal solutions. A compromise solution was selected from the Pareto solutions by using the mapping method. Experiments with the same parameter settings were compared with the simulations. After conducting radial forging and mechanical property experimental study on the forging product by multi-objective optimization process parameters, the feasibility of the multi-objective optimization method for the precision forging product forming quality was verified. © 2015 Springer-Verlag London Source


Zhu F.,Wuhan University of Science and Technology | Wang Z.,Wuhan University of Science and Technology | Lv M.,Chongqing Construction Industrial group CO.
Advances in Materials Science and Engineering | Year: 2015

In order to control the precision forging forming quality and improve the service life of die, a multiobjective optimization method for process parameters design was presented by applying Latin hypercube design method and response surface model approach. Meanwhile the deformation homogeneity and material damage of forging parts were proposed for evaluating the forming quality. The forming load of die was proposed for evaluating the service life of die. Then as a case of study, the radial precision forging for a hollow shaft with variable cross section and wall thickness was carried out. The 3D rigid-plastic finite element (FE) model of the hollow shaft radial precision forging was established. The multiobjective optimization forecast model was established by adopting finite element results and response surface methodology. Nondominated sorting genetic algorithm-II (NSGA-II) was adopted to obtain the Pareto-optimal solutions. A compromise solution was selected from the Pareto solutions by using the mapping method. In the finite element study on the forming quality of forging parts and the service life of dies by multiobjective optimization process parameters, the feasibility of the multiobjective optimization method presented by this work was verified. © 2015 Fayuan Zhu et al. Source


Wang Z.,Wuhan University of Science and Technology | Zhu F.,Wuhan University of Science and Technology | Lu M.,Chongqing Construction Industrial group CO. | Wang F.,Wuhan University of Science and Technology
Huazhong Keji Daxue Xuebao (Ziran Kexue Ban)/Journal of Huazhong University of Science and Technology (Natural Science Edition) | Year: 2015

Based on the characteristics of low-loading strengthening for material design, a new type of steering drive axle variable diameter hollow half shaft structure was designed, and its three-dimensional mode including imperial involute spline teeth, reasonable transition fillet and other fine features was established. The modal vibration mode, equivalent stress and fatigue life of the mechanical characteristics of the new type half shaft were analyzed by finite element methods. The results show that the first ten order non-zero mode of half shaft is mainly bending deformation, and the natural frequency of the new half shaft and the solid half shaft is similar, which can avoid resonance effectively during the half shaft using process. Maximum equivalent stress of new half shaft occurs to the end of transition fillet, and less than torsional strength of the half shaft material, which satisfies the requirements for strength design of the shaft. When the torque of the new half shaft is 1 500 N?m under cyclic loading, the minimum fatigue life occurs to the end of transition fillet, which is coinciding with the half shaft stress concentration of the node position, so cold precision forging and axial cold extrusion spline molding technology should be used to improve the intensity and working life of the new type half shaft in practical production processing and manufacturing. ©, 2015, Huazhong University of Science and Technology. All right reserved. Source


Wang Z.,Wuhan University of Science and Technology | Zhu F.,Wuhan University of Science and Technology | Lu M.,Chongqing Construction Industrial group CO. | Chen S.,Wuhan University of Science and Technology
Qiche Gongcheng/Automotive Engineering | Year: 2015

A lightweight design method is proposed for the hollow half shaft of a vehicle steering drive axle based on the combination of numerical optimization and finite element simulation. An optimization model for the lightweighting of half shaft is set up with the thicknesses and lengths of different parts and the transitional angle of half shaft as design variables, minimizing the mass of half shaft as optimization objective, and the 2nd order constrained mode frequency and the equivalent stress at the filleted corner of spline end as constraints. A numerical simulation experiment combination of ten design variables with three levels each is determined by using orthogonal experimental design, a response surface approximation model for the half shaft is established by using least squares method, and an iteration optimization is conducted on the model with sequential quadratic programming algorithm. The results show that after lightweighting optimization the mass of hollow half shaft reduces by 16.7g, the frequency of 2nd order constrained mode increases by 0.6Hz, and the equivalent stresses at both the filleted corner of spline end and the location with smallest diameter are lower than the torsional strength of half shaft material. © 2015, SAE-China. All right reserved. Source

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