Title: Optimisation of pass schedules for flat-tool forging based on analytical method

Authors: Guowei Feng; Zhenshan Cui; Wen Chen

Addresses: National Engineering Research Center for Die and Mold CAD, Institute of Forming Technology and Equipment, Shanghai Jiao Tong University, 1954 Huashan Road, Shanghai 200030, China ' National Engineering Research Center for Die and Mold CAD, Institute of Forming Technology and Equipment, Shanghai Jiao Tong University, 1954 Huashan Road, Shanghai 200030, China ' National Engineering Research Center for Die and Mold CAD, Institute of Forming Technology and Equipment, Shanghai Jiao Tong University, 1954 Huashan Road, Shanghai 200030, China

Abstract: For the incremental bulk forming, semi-empirical analytical methods take great advantage in forming process planning due to their efficiency in calculating deformation and temperature for the whole process. In this paper, based on explicit differential method, a model to predict the evolution of temperature during forging process is proposed. By incorporating this model with the semi-analytical model for deformation presented earlier by the authors, an efficient simulation method for analysing open-die forming process is established. A case study is carried out and the results of deformation and temperature fields predicted by using presented analytical method are quite close to those predicted by finite element method. A set of process schedules are designed and an optimisation is carried out according to the proposed evaluation indexes. The results show that comparatively larger feed ratio and smaller reduction ratio are more favourable to obtain better deformation homogeneity and compact effect.

Keywords: flat-tool forging; analytical modelling; pass schedules; optimisation; scheduling; incremental bulk forming; simulation; open die forming; deformation; temperature prediction.

DOI: 10.1504/IJMPT.2015.072566

International Journal of Materials and Product Technology, 2015 Vol.51 No.4, pp.385 - 400

Received: 25 Jul 2014
Accepted: 13 Mar 2015
Published online: 19 Oct 2015 *

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