UPPER-BOUND ANALYSIS FOR THE AUTOMATION OF OPEN-DIE FORGING

The automation of open-die forging systems can be attractive for small batch manufacture of medium-size parts where they can compete against a number of machining processes. The introduction of new manufacturin g systems and the associated work-in-progress minimization technique p rompts a consideration of the use of open-die forging for incremental profiling and shaping processes. In order to develop an automated open -die forging process it is essential to be able to predict the shape c hanges occurring at each step. Therefore a general computerized method ology is proposed for small batch manufacture via a theoretical model, producing rapid predictions of metal how for continuing incremental d eformation. This paper reviews the open-die forging process in this co ntext as a part of a computer-controlled robotics flexible forging sys tem for the economic production of small-batch quantities. The metal f low in open-die forging is analyzed through a number of upper-bound so lutions and the basis of an on-line analytical modeling system, togeth er with experimental correlation and a planning system, is presented t o produce bar profile features. (C) 1997 Published by Elsevier Science S.A.