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Hao Hu, Fan Zhao, Daoxiang Wu, Zhengan Wang, Zhilei Wang, Zhihao Zhang, Weidong Li, and Jianxin Xie, Digital model for rapid prediction and autonomous control of die forging force for aluminum alloy aviation components, Int. J. Miner. Metall. Mater., (2025). https://doi.org/10.1007/s12613-025-3114-x
Hao Hu, Fan Zhao, Daoxiang Wu, Zhengan Wang, Zhilei Wang, Zhihao Zhang, Weidong Li, and Jianxin Xie, Digital model for rapid prediction and autonomous control of die forging force for aluminum alloy aviation components, Int. J. Miner. Metall. Mater., (2025). https://doi.org/10.1007/s12613-025-3114-x
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铝合金航空构件模锻成形力快速预测和自主控制的数字模型

摘要: 模锻过程的数字化建模和自主控制是实现零件高质量智能锻造的重要挑战。本文以AA2014铝合金航空模锻件为例,提出了一种基于机器学习的锻造力数字建模和应对锻造工艺参数扰动的自主控制方法。首先,在不同的摩擦因子、坯料温度、模具温度和压下速度条件下进行锻造过程有限元模拟,获得了工艺参数-不同锻造行程下的锻造力数据。采用支持向量回归算法建立了锻造力预测基础模型,其中锻模完全充满锻造力Ff的预测误差达到4.1%以下。然后,为提高模型对实际Ff的预测精度,采用贝叶斯优化算法进行了两轮锻造实验迭代,实际Ff的预测误差由6.0%降低至1.5%。最后,采用Ff预测模型结合遗传算法,建立了坯料温度和模具温度发生扰动时锻造各阶段压下速度的自主优化策略,实现了应对扰动的自主控制。在模具和坯料温度发生−20或−40°C扰动的情况下,采用自主优化策略进行锻造实验,可将实际Ff保持在目标值180 t左右,相对误差范围为−1.3%至+3.1%。本文的工作可为锻造过程数字建模和质量自主优化控制提供参考。

 

Digital model for rapid prediction and autonomous control of die forging force for aluminum alloy aviation components

Abstract: Digital modeling and autonomous control of the die forging process are significant challenges in realizing high-quality intelligent forging of components. Using the die forging of AA2014 aluminum alloy as a case study, a machine-learning-assisted method for digital modeling of the forging force and autonomous control in response to forging parameter disturbances was proposed. First, finite element simulations of the forging processes were conducted under varying friction factors, die temperatures, billet temperatures, and forging velocities, and the sample data, including process parameters and forging force under different forging strokes, were gathered. Prediction models for the forging force were established using the support vector regression algorithm. The prediction error of Ff, that is, the forging force required to fill the die cavity fully, was as low as 4.1%. To further improve the prediction accuracy of the model for the actual Ff, two rounds of iterative forging experiments were conducted using the Bayesian optimization algorithm, and the prediction error of Ff in the forging experiments was reduced from 6.0% to 1.5%. Finally, the prediction model of Ff combined with a genetic algorithm was used to establish an autonomous optimization strategy for the forging velocity at each stage of the forging stroke, when the billet and die temperatures were disturbed, which realized the autonomous control in response to disturbances. In cases of −20 or −40°C reductions in the die and billet temperatures, forging experiments conducted with the autonomous optimization strategy maintained the measured Ff around the target value of 180 t, with the relative error ranging from −1.3% to +3.1%. This work provides a reference for the study of digital modeling and autonomous optimization control of quality factors in the forging process.

 

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