Physics-Informed Preform Design for Flashless 3D Forging via Material Point Backtracking and Finite Element Simulations
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 nea...
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MDPI AG
2025-06-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/9/6/202 |
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| author | Gracious Ngaile Karthikeyan Kumaran |
| author_facet | Gracious Ngaile Karthikeyan Kumaran |
| author_sort | Gracious Ngaile |
| collection | DOAJ |
| description | 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. |
| format | Article |
| id | doaj-art-cbaedcdbc1fe4dbf9fe3872ab3a30e7a |
| institution | OA Journals |
| issn | 2504-4494 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | MDPI AG |
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| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-cbaedcdbc1fe4dbf9fe3872ab3a30e7a2025-08-20T02:21:10ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-06-019620210.3390/jmmp9060202Physics-Informed Preform Design for Flashless 3D Forging via Material Point Backtracking and Finite Element SimulationsGracious Ngaile0Karthikeyan Kumaran1Department of Mechanical and Aerospace Engineering, North Carolina State University, Raleigh, NC 27695, USADepartment of Mechanical and Aerospace Engineering, North Carolina State University, Raleigh, NC 27695, USAAccurate 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.https://www.mdpi.com/2504-4494/9/6/202forgingpreform designflashless forgingfinite element simulation |
| spellingShingle | Gracious Ngaile Karthikeyan Kumaran Physics-Informed Preform Design for Flashless 3D Forging via Material Point Backtracking and Finite Element Simulations Journal of Manufacturing and Materials Processing forging preform design flashless forging finite element simulation |
| title | Physics-Informed Preform Design for Flashless 3D Forging via Material Point Backtracking and Finite Element Simulations |
| title_full | Physics-Informed Preform Design for Flashless 3D Forging via Material Point Backtracking and Finite Element Simulations |
| title_fullStr | Physics-Informed Preform Design for Flashless 3D Forging via Material Point Backtracking and Finite Element Simulations |
| title_full_unstemmed | Physics-Informed Preform Design for Flashless 3D Forging via Material Point Backtracking and Finite Element Simulations |
| title_short | Physics-Informed Preform Design for Flashless 3D Forging via Material Point Backtracking and Finite Element Simulations |
| title_sort | physics informed preform design for flashless 3d forging via material point backtracking and finite element simulations |
| topic | forging preform design flashless forging finite element simulation |
| url | https://www.mdpi.com/2504-4494/9/6/202 |
| work_keys_str_mv | AT graciousngaile physicsinformedpreformdesignforflashless3dforgingviamaterialpointbacktrackingandfiniteelementsimulations AT karthikeyankumaran physicsinformedpreformdesignforflashless3dforgingviamaterialpointbacktrackingandfiniteelementsimulations |