Multi-objective optimisation of forging process parameters of Ti-6Al-4V alloy connecting rod based on orthogonal experiment

• Published in: Materials today communications 2025-01, Vol.42, p.111296, Article 111296
• Main Authors: Deng, Wei, Wang, Zhuoan, He, Gehao, Zhang, Haifeng, Yu, Mingjiang, Jia, Dewen
• Format: Article
• Language: English
• Subjects: Connecting rod; Forging; Process optimisation; Ti-6Al-4V alloy
• ISSN: 2352-4928; 2352-4928
• DOI: 10.1016/j.mtcomm.2024.111296

To devise a green manufacturing process for the hot forging and forming of Ti-6Al-4V alloy connecting rods, a multi-objective optimisation was conducted using a combination of orthogonal test and numerical simulations based on the Deform-3D platform. Four process parameters, namely initial forging temperature, forging speed, flattening rate, and friction factor were considered as factors affecting the performance of the connecting rods, and their influence on four evaluation indicators, namely energy consumption per unit volume, maximum forming load, deformation uniformity, and maximum effective stress was investigated. The preferred solution was determined by visual and extreme variance analyses, and an optimal solution was obtained for the manufacture of the Ti-6Al-4V alloy connecting rods using integrated frequency analysis; furthermore, a comparative analysis of the quality of the connecting rods and energy consumption before and after the optimisation was conducted, by which it was found that the initial temperature of the forging billet had the greatest influence on the energy consumption and quality of the hot forging and forming process. With the optimised process parameters, energy consumption per unit volume decreased from 658.37 to 417.16 J/mm3, i.e., a saving of 31.15 %; maximum forming load was reduced by 20.18 % from 6560.36 to 5236.42 kN; maximum effective stress decreased by 2.73 % from 226 to 220 MPa; and the deformation uniformity was reduced by 10.52 % from 0.656 to 0.587. The optimised process was used to forge test samples, and it was verified that the process could achieve normal metal filling without any forging defects, thereby accomplishing green manufacture of Ti-6Al-4V alloy connecting rods. [Display omitted]