Real-Time Process Characterization of Open Die Forging for Adaptive Control

2000 ◽  
Vol 123 (4) ◽  
pp. 511-516 ◽  
Author(s):  
T. J. Nye ◽  
A. M. Elbadan ◽  
G. M. Bone
Keyword(s):  
Adaptive Control ◽  
Real Time ◽  
Program Control ◽  
Time Process ◽  
Forming Process ◽  
Plastic Deformations ◽  
Die Forging ◽  
Process Characterization ◽  
Open Die Forging

Open die forging is a process in which products are made through repeated, incremental plastic deformations of a workpiece. Typically, the workpiece is held by a manipulator, which can position the workpiece through program control between the dies of a press. The part programs are generated with an empirically derived parameter, called the spread coefficient, whose value is subject to some contention. In this work, we demonstrate how process information can be used in real time to derive the actual spread coefficient for a given workpiece as it is being formed. These measurements and calculations occur in real time, and can be used to regenerate part programs to optimize the forming process, or can be used to adaptively control each incremental deformation of the workpiece.

Real-Time Process Characterization of Open Die Forging for Adaptive Control

2000 ◽  
Author(s):  
T. J. Nye ◽  
A. M. Elbadan ◽  
G. M. Bone
Keyword(s):  
Adaptive Control ◽  
Real Time ◽  
Program Control ◽  
Time Process ◽  
Forming Process ◽  
Plastic Deformations ◽  
Die Forging ◽  
Process Characterization ◽  
Open Die Forging

Abstract Open die forging is a process in which products are made through repeated, incremental plastic deformations of a workpiece. Typically, the workpiece is held by a manipulator, which can position the workpiece through program control between the dies of a press. The part programs are generated with an empirically derived parameter, called the spread coefficient, whose value is subject to some contention. In this work, we demonstrate how process information can be used in real time to derive the actual spread coefficient for a given workpiece as it is being formed. These measurements and calculations occur in real time, and can be used to regenerate part programs to optimize the forming process, or can be used to adaptively control each incremental deformation of the workpiece.

Adaptive Control for Intelligent Open Die Forging

2004 ◽  
Author(s):  
Wensheng Liu ◽  
T. J. Nye
Keyword(s):  
Adaptive Control ◽  
Manufacturing Process ◽  
Flexible Manufacturing ◽  
A Priori ◽  
Raw Material ◽  
Cross Sectional ◽  
Geometry Model ◽  
Die Forging ◽  
Process Feedback ◽  
Open Die Forging

Open die forging is a manufacturing process with a number of advantages; in particular it is an inherently flexible manufacturing process that makes efficient use of raw material. A fundamental drawback of this process, however, is the difficulty found in creating forging programs to control part manipulation and forming steps. A-priori approaches to creating these programs, such as by using FEM simulations or using modeling materials, are slow and have a strong tendency for errors to accumulate when predicting the results of consecutive forming steps. In this paper we present a new approach in which process feedback is used between forming steps to update a part geometry model that allows the forming sequence to be adjusted adaptively. This approach has been implemented in a simulated forging cell that uses non-linear FEM analyses to predict the effects of each forming step. A fully adaptive control scheme has been implemented that efficiently forges bars of one cross sectional shape into another shape, such as square to round or hexagonal. Programming the forging system with this scheme has proved particularly simple; the shape of the raw material is measured, and a desired shape is specified. Physical experiments have confirmed the simulation results.

scholarly journals A New Cross Wedge Rolling Process for Producing Rail Axles

2018 ◽  
Vol 190 ◽  
pp. 11006 ◽  
Author(s):  
Zbigniew Pater ◽  
Janusz Tomczak
Keyword(s):  
Rolling Process ◽  
Roll Design ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
New Techniques ◽  
Rotary Forging ◽  
Large Size ◽  
Die Forging ◽  
Open Die Forging ◽  
Hammer Forging

Rail axles are large-size parts produced in large batches. Currently, these parts are produced by metal forming techniques such as rotary forging, open die forging with hydraulic presses and open die hammer forging (minimum ram weight: 3 Mg). Nevertheless, not only are the above methods far from being efficient, they also lack accuracy (open die forging). As a result, new techniques for producing rail axles are constantly developed. One of such alternative techniques is based on the use of cross wedge rolling (CWR), which is the subject of the present study. An innovative roll design for producing rail axles by CWR is proposed. The rolls are provided with three pairs of wedge tools that act simultaneously on the workpiece and form the part in one revolution of the rolls, i.e., during 20 s. The numerical modelling of a CWR process with the proposed roll design reveals that the solution can be used to produce railway axles with the desired geometry. This technique, however, requires relatively high loads and torques. To decrease the force parameters, the forming process was modified and ran in two operations. The first operation consists in forming the central step of the workpiece while the other one involves the formation of steps on the ends of the workpiece. The results of the new simulation show a significant decrease in the loads and torques, which is caused, among others, by reducing the nominal diameter of the rolls from 1600 mm to 1200 mm. The numerical findings can be used to design a rolling mill for producing rail axles.

The Numerical Simulation of Conductive Body Forming Process and Mould Design

2011 ◽  
Vol 704-705 ◽  
pp. 177-182
Author(s):  
Jian Xin Gao ◽  
Pei Feng Zhao ◽  
Ke Xing Song ◽  
Qing Wang
Keyword(s):  
Numerical Simulation ◽  
Machining Process ◽  
Forming Process ◽  
Die Forging ◽  
Conductive Body ◽  
Closed Die Forging ◽  
Draft Angle ◽  
Simulation Results ◽  
Open Die Forging ◽  
Ring Blank

T2-copper conductive body is a important part used in high voltage switch, it has poor machining process due to the complex shape. Through Deform numerical simulation, conductive body was formed by open-die forging and closed die forging. In the open-die forging simulation，heat transfer coefficient between blank (880°C) and open-die (200°C) is 11, the surrounding environment temperature is 20°C, friction factor is 0.3. The main open-die forging process parameters is: outer draft angle α=6.5°; inner draft angle β＝10°; bridge width b＝5、8、11mm. punching skin and cylindrical blank. Simulation results show that forging can meet the requirement while properly adjusting mould parameters. The main size of closed-die forging working parts is designed according to the conductive body graph, no draft angle and ring blank of external diameter Φ111mm and inside diameter Φ93mm with the same volume of conductive body. The simulation results shows that forging can be formed using open-die forging, and it is difficult to form product by the process of the closed-die forging for ring blank because of the restriction of solid state metal liquidity, many regions of the filling is not sufficient. Open-die forging and casting blank-closed die forging are both used in actual production. The casting blank-closed die forging is a more reasonable forming process compared with the open-die forging as metal volume of distribution is solved, higher utilization rate of material, more simple process in following work and the like. To make it more suitable for practical production, appropriate adjustments of some parameters was made in the mold design process based on the numerical simulation. Keywords: open-die forging; casting blank–closed die forging; numerical simulation

Sign in / Sign up

Export Citation Format

Share Document