Intelligent Control and Optimal Design System for Metal Forming Processes

A new process design method for controlling microstructure development during hot metal deformation processes was developed. This approach is based on modern control theory and involves state-space models for describing the material behavior and the mechanics of the process. The challenge of effectively controlling the values and distribution of important microstructural features can now be systematically formulated and solved in terms of an optimal control problem. This method has been applied to the optimization of grain size and certain process parameters such as die geometry profile and applied to the optimization of grain size and certain process parameters such as die geometry profile and ram velocity during extrusion of plain carbon steel. Various case studies have been investigated, and experimental results show good agreement with those predicted in the design stage. A software product for Microstructure Trajectory Optimization was developed, and it is now ready for beta site testing. Modeling and simulation of metal forming equipment was done to better understand and improve the control of metal forming equipment. Techniques were developed for creating accurate models and computer simulations of metal forming equipment for the purpose of improving metal forming process design. Special emphasis was placed on modeling the dynamic behavior of hydraulic vertical forge presses, although similar principles apply to other types of metal forming equipment.