A New Approach to Preform Design in Metal Forging Processes Based on the Convolution Neural Network

Abstract

This study presents an innovative methodology for preform design in metal forging processes based on the convolution neural network (CNN) algorithm. The proposed approach extracts the features of inputted forging product geometries and utilizes them to derive the corresponding preform shapes by employing weight arrays (filters) determined during the convolutional operations. The filters are progressively updated during the training process, emulating the learning steps of a process engineer responsible for the design of preform shapes for the forging processes. The design system is composed of multiple three-dimensional (3D) CNN sub-models, which can automatically derive individual 3D preform design candidates. It also implies that the 3D surfaces of preforms are easily acquired, which is important for the forging industry. The proposed preform design methodology was validated by applying it to two-dimensional (2D) axisymmetric shapes, one-quarter plane-symmetric 3D shapes, and two other industrial cases. In all the considered cases, the design methodology achieved substantial reductions in the forging load without forging defects, proving its reliability and effectiveness for application in metal forging processes.