USAGE OF TOPOLOGICAL OPTIMIZATION IN DESIGN OF MECHANICAL FORGING PRESSES

Abstract

This article deals with the usage of topological optimization method in the design of mechanical forging press. This area of industry is worldwide without significant development changes for long time. Topological optimization is used here for minimizing weight of forging press and maximizing stiffness of whole machine. Mechanical press with nominal force 80 MNis used as an example.  Frame of press is made from two separate crossbeams and two preloaded columns. The article describes application of optimization methods for welded and also for casted frame of press. Remodeling and verification is performed for welded steel frame.Three optimization tools (FEM codes Tosca, NX Nastran and Frustum) were used for optimization.Main focus is here on upper and lower crossbeam. Optimization theory and parameters (design area, design objective and design variables) are described here from computational point of view. Method called “compliance” and “weight minimizing”was used with respect to considered machine. The simulation model for optimization is considering whole assembly of forging press. Submodeling was used as second step for refinement of results. Loading cases were considering centric and eccentric loading of press. All results were used to create new design of crossbeams for mechanical forging press with nominal forging force 80 MN.