A finite element based sensitivity analysis method for preform die shape design in metal forging is developed. Theoptimization goal is to obtain more uniform deformation within the final forging by controlling the deformationuniformity. The objective function expressed by the effective strain is constructed. The sensitivity equations of theobjective function, elemental volume, elemental effective strain rate and the elemental strain rate with respect to thedesign variables are constituted. The preform die shapes of an H-shaped forging process in axisymmetric deformationare designed using this method.
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