COMPUTER MODELING OF TOOL LOADS AND PRESS TOOL DEFLECTIONS IN MULTISTAGE FORGING

A mathematical model of the deflections arising during forging in a mu ltistage press provides the basis for the development of a computer pa ckage which can be used to predict the dimensional changes in workpiec es occurring at each stage, due to a change at any one stage and indiv idual tool loads and total press load for any given set of conditions. The program can be used to speed up tool setting times by enabling th e correct shut-heights for each forming stage to be determined without trial and error. It can be used also to investigate the effects of ch anges (either deliberate or unintentional) in process conditions such as: lubrication, billet volume or hardness, on the dimensions of the f inish forged component. The program has been validated by comparing it s output with the results of experiments comprising: single-stage, two -stage and three-stage forgings undertaken on a vertical crank press.