Sensitivity analysis of near solidus forming (NSF) process with digital twin using Taguchi approach

doi:10.1007/s40436-024-00482-4

Advances in Manufacturing ›› 2025, Vol. 13 ›› Issue (2): 322-336.doi: 10.1007/s40436-024-00482-4

Sensitivity analysis of near solidus forming (NSF) process with digital twin using Taguchi approach

Muhammad Sajjad¹, Javier Trinidad¹, Gorka Plata¹, Jokin Lozares², Joseba Mendiguren¹

1. Faculty of Engineering, Mechanics and Industrial Production, Mondragon Unibertsitatea, Loramendi 4, 20500, Mondragon, Gipuzkoa, Spain;
2. Department of Mechanics, Design and Industrial Management, University of Deusto, Avda. de las Universidades 24, 48007, Bilbao, Spain

收稿日期:2023-07-06 修回日期:2023-09-23 发布日期:2025-05-16
通讯作者: Muhammad Sajjad,E-mail:msajjad@mondragon.edu E-mail:msajjad@mondragon.edu
作者简介:Muhammad Sajjad born in 1994, currently he is doing his Ph.D. degree from Mondragon University, Spain. His research work is mainly focused on the development of digital twin (DT) for the prediction of Near Solidus Forming (NSF) process at the industrial scale. His previous work includes numerical modeling/simulation and experimentation of aluminium alloys in the f ield of met al for ming processes.
Javier Trinidad is a researcher at the Advanced Materials Forming group at MGEP (Mondragon University) since October 2018. He has extensive experience in the field of process and product optimization, material characterization and tool design.
Gorka Plata born in 1991, is cur rently a lecturer and researcher at Mondragon University. He received his Ph.D. degree in 2018 with a specialization in manufacturing processes. His research focus is in the field of semi-solid forging (SSF) process. He is working on various European projects and supervising master’s and Ph.D. students.
Jokin Lozares is a member of Advanced Industrial Manufacturing at the University of Deusto. He holds a degree in Materials Engineering from the Bilbao School of Engineering and a Ph.D. from Mondragon Unibertsitatea. He worked on the development and industrial implementation of semi-solid forming of steels. In short, he has extensive experience in casting and forging processes.
Joseba Mendiguren born in 1984, received his Ph.D. degree from Mondragon University. Currently, he is a member of Advanced Material Forming research group at Mondragon Unibertsitatea. He has more than 10 years of research experience in the field of metal forming processes which includes material characterization, model development, and so on. Dr Mendiguren has worked in more than 60 research projects, all in closed collaboration with industry and partially founded by local, regional, national and European governments.

Sensitivity analysis of near solidus forming (NSF) process with digital twin using Taguchi approach

Muhammad Sajjad¹, Javier Trinidad¹, Gorka Plata¹, Jokin Lozares², Joseba Mendiguren¹

1. Faculty of Engineering, Mechanics and Industrial Production, Mondragon Unibertsitatea, Loramendi 4, 20500, Mondragon, Gipuzkoa, Spain;
2. Department of Mechanics, Design and Industrial Management, University of Deusto, Avda. de las Universidades 24, 48007, Bilbao, Spain

Received:2023-07-06 Revised:2023-09-23 Published:2025-05-16
Contact: Muhammad Sajjad,E-mail:msajjad@mondragon.edu E-mail:msajjad@mondragon.edu

摘要/Abstract

摘要： Forging at near solidus material state takes advantage of the high ductility of the material at the semi solid or soft-solid state while keeping most of the mechanical properties of a forged part. The technology is at maturity level ready for its industrial implementation. However, to implement the process for complex cases the development of an appropriate digital twin (DT) is necessary. While developing a material model, a strong experimental and DT is necessary to be able to evaluate the accuracy of the model. Aimed at having a reliable DT under control, for future material model validations, the main objective of this work is to develop a sensitivity analysis of three NSF industrial cases such as Hook, R spindle and H spindle to develop an adequate DT calibration procedure. Firstly, the benchmark experimentation process parameter noise and experimentation boundary conditions (BCs) parameter uncertainty are identified. Secondly, the three industrial benchmark DTs are constructed, and a Taguchi design of experiments (DoEs) methodology is put in place to develop the sensitivity analysis. Finally, after simulations the results are critically evaluated and the sensitivity of each benchmark to the different inputs (process parameter noise and BC parameter uncertainty) is studied. Lastly, the optimum DT calibration procedure is developed. Overall, the results stated the minimum impact of the material model in terms of dies filling. Nevertheless, even if the material model is the highest impacting factor for the forging forces other inputs, such as heat transfer and friction must be under control first.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00482-4

关键词: Near solidus, Digital twin (DT), Taguchi design, Sensitivity analysis, Heat transfer

Abstract: Forging at near solidus material state takes advantage of the high ductility of the material at the semi solid or soft-solid state while keeping most of the mechanical properties of a forged part. The technology is at maturity level ready for its industrial implementation. However, to implement the process for complex cases the development of an appropriate digital twin (DT) is necessary. While developing a material model, a strong experimental and DT is necessary to be able to evaluate the accuracy of the model. Aimed at having a reliable DT under control, for future material model validations, the main objective of this work is to develop a sensitivity analysis of three NSF industrial cases such as Hook, R spindle and H spindle to develop an adequate DT calibration procedure. Firstly, the benchmark experimentation process parameter noise and experimentation boundary conditions (BCs) parameter uncertainty are identified. Secondly, the three industrial benchmark DTs are constructed, and a Taguchi design of experiments (DoEs) methodology is put in place to develop the sensitivity analysis. Finally, after simulations the results are critically evaluated and the sensitivity of each benchmark to the different inputs (process parameter noise and BC parameter uncertainty) is studied. Lastly, the optimum DT calibration procedure is developed. Overall, the results stated the minimum impact of the material model in terms of dies filling. Nevertheless, even if the material model is the highest impacting factor for the forging forces other inputs, such as heat transfer and friction must be under control first.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00482-4

Key words: Near solidus, Digital twin (DT), Taguchi design, Sensitivity analysis, Heat transfer

Muhammad Sajjad, Javier Trinidad, Gorka Plata, Jokin Lozares, Joseba Mendiguren. Sensitivity analysis of near solidus forming (NSF) process with digital twin using Taguchi approach[J]. Advances in Manufacturing, 2025, 13(2): 322-336.

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Sensitivity analysis of near solidus forming (NSF) process with digital twin using Taguchi approach

Sensitivity analysis of near solidus forming (NSF) process with digital twin using Taguchi approach

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