Hot Forging of Automobile Steel Gear Blanks: An Exploration of the Solution Space

In this paper, we explore the design space associated with the realization of automobile steel gear blanks manufactured using hot forging. ABAQUS, a commercially available software package, is used to simulate the hot forging process. Surrogate models are developed and used to model the solution space. Then the compromise Decision Support Problem (cDSP) is used to explore the feasible space. Results are presented as ternary plots that allow a designer to visualize the trade-offs between competing goals such as reducing the size of the underfill, reducing the flash (excess material), waste of forged materials, energy required for deformation and crack susceptibility, on various possible solutions. The efficacy of the exploration of the design space and trade-offs between competing solutions is illustrated.