Physics-Informed Preform Design for Flashless 3D Forging via Material Point Backtracking and Finite Element Simulations
Year: 2025
Type: article
Abstract: Accurate preform design in forging processes is critical for improving part quality, conserving material, reducing manufacturing costs, and eliminating secondary operations. This paper presents a finite element (FE) simulation-based methodology for preform design aimed at achieving flashless and near-flashless forging. The approach leverages material point backtracking within FE models to generate physics-informed preform geometries that capture complex material flow, die geometry interactions, and thermal gradients. An iterative scheme combining backtracking, surface reconstruction, and point-cloud solid modeling was developed and applied to several three-dimensional forging case studies, including a cross-joint and a three-lobe drive hub. The methodology demonstrated significant reductions in flash formation, particularly in parts that traditionally exhibit severe flash under conventional forging. Beyond supporting the development of new flashless forging sequences, the method also offers a framework for modifying preforms during production to minimize waste and for diagnosing preform defects linked to variability in frictional conditions, die temperatures, or material properties. Future integration of the proposed method with design of experiments (DOE) and surrogate modeling techniques could further enhance its applicability by optimizing preform designs within a localized design space. The findings suggest that this approach provides a practical and powerful tool for advancing both new and existing forging production lines toward higher efficiency and sustainability.
DOI: 10.3390/jmmp9060202
Authors: Gracious Ngaile, Karthikeyan Kumaran
Institution: North Carolina State University
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $2,172
OpenAlex ID: W4411420279