A new forging preform design approach using reverse simulation

A new reverse simulation approach for the optimal design of forging preforms using the Tetrahedral Element Upper Bound Analysis (TEUBA) is presented. The approach employs a criterion based on the concept of the material distribution to determine the boundary condition and to evaluate the complexity of the deformed shapes resulting from reverse simulations. The approach aims to predict an initial billet section which is close to a rectangle as ideal, or a preform shape where preform stages are required. The produced preforms are assessed by performing forward simulations with a commercial modelling package. The approach is shown to have a considerable potential in preform design.