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.