Intelligent Generation Method of Free Forging Process Pass Schedule Based on Process Templates and Case Database

Abstract

This invention belongs to the field of intelligent manufacturing technology and discloses an intelligent generation method for free forging process pass tables based on process templates and case databases. The method is based on a B / S architecture system, collecting input parameters such as material properties and geometric dimensions, and matching them with standard process templates. Then, combining heating regimes and historical data from the case database, it plans the heat cycle division and intermediate target dimensions. Through a process-driven iterative algorithm, it dynamically calculates the reduction, feed rate, and flipping strategy for each pass based on the law of constant volume. Subsequently, a three-layer process pass table with heat cycle, process, and pass structure is generated. After visual interactive correction and cascaded consistency verification, the reliability of the scheme is verified through finite element simulation. Finally, the verified scheme is stored in the database and a traceability mechanism is established. This invention solves the problems of traditional free forging process design relying on manual experience, low efficiency, and difficulty in knowledge reuse, realizing the structured accumulation of process knowledge and the automated generation of production instructions.

Description

Technical Field

[0001] This invention belongs to the field of intelligent manufacturing technology, and in particular relates to an intelligent generation method for free forging process pass tables based on process templates and case databases. Background Technology

[0002] Free forging is a core process in the manufacturing of large forgings, and the rationality of its process design directly determines the internal quality, dimensional accuracy, and production efficiency of the forgings. Currently, the compilation of free forging process pass schedules mainly relies on the manual experience of process engineers. Engineers need to comprehensively consider factors such as material grade, heating regime, equipment capacity, and target dimensions, manually determine the heat treatment process, process path, and calculate the reduction, feed rate, rotation angle, and intermediate dimensional changes for each pass. Finally, the results are compiled into a process card or pass schedule.

[0003] This manual data compilation method has several technical drawbacks: First, the process design involves multiple variable constraints and complex iterative calculations, resulting in extremely low standardization and susceptibility to human error, which can lead to errors in the process plan and affect the quality of forgings. Second, the design efficiency is low; for forgings of different specifications and materials, a large amount of repetitive calculation work is required, which is difficult to meet the needs of large-scale production. Third, historical production cases, quality results, and other process knowledge are mostly stored in scattered documents and tables, lacking structured management and failing to achieve rapid retrieval and reuse, making it difficult to accumulate and pass on process experience and form a calculable knowledge system. Fourth, material data, equipment data, and process template data are fragmented, failing to provide unified data support for enterprise-level integrated process design and hindering the digital transformation of the free forging industry.

[0004] Therefore, there is an urgent need to develop a method that can realize the structured expression of free forging process knowledge, the automated generation of process pass tables, and intelligent optimization by linking with historical cases, in order to solve the problems of reliance on manual labor, low efficiency, and poor knowledge reusability in existing technologies. Summary of the Invention

[0005] To at least partially solve the technical problems existing in the prior art, the present invention provides a method for intelligently generating a free forging process pass table based on process templates and a case database.

[0006] The intelligent generation method for free forging process pass table based on process templates and case database of the present invention is implemented in a free forging process design system with B / S architecture. The method includes the following steps: S1: Data Acquisition and Standardization: Parameters for free forging process design are acquired and input through a human-computer interaction interface. The acquired and input parameters include at least material property parameters, initial geometric parameters of the billet, target forging size parameters, and process constraints. The parameters are then converted into structured calculation input vectors. S2: Template matching and path planning: Based on the process type and forging characteristics in the parameters, match the corresponding standard process template from the preset process template library. The standard process template defines the logic of the number of firing cycles, the order of the processes, and the deformation calculation rules for each process. S3: Heat Division and Intermediate Target Establishment: Based on the matching standard process template, combined with heating regime parameters and allowable material deformation, the heat division scheme is automatically planned to determine the starting size, ending size and allowable process set of each heat. During this process, historical similar case data in the case database are called to refer to or correct the intermediate target size. S4: Iterative calculation of pass parameters: According to the determined set of processes, the built-in algorithm engine performs iterative calculation of each pass. Under the condition of meeting the equipment capacity and forming process constraints, the reduction amount, feed amount and flip angle are derived for each pass, and the geometric dimensions of the billet are updated in real time according to the law of constant volume until the termination dimension of the pass is reached. S5: Data Model Construction and Display: Reconstruct the discrete data generated by iterative calculation into a hierarchical process pass table and display it in a visualization interface; S6: Interactive Correction and Solution Entry: Respond to user correction operations on process pass parameters and perform cascaded consistency checks. After confirming that there are no errors, the final generated process pass table is associated with the case database for storage.

[0007] Furthermore, in the above-mentioned intelligent generation method for free forging process pass table based on process templates and case databases, in step S2, the definition structure of the standard process template includes at least the following three layers: Topology layer: Defines the logical order between firing cycles and the integrated process sequence within each firing cycle. The process sequence includes one or more of the following processes: pressing the handle, chamfering, upsetting, flattening, axial elongation, rounding, bottom cutting, and shaping. The computational logic layer defines the deformation criterion formula index and intermediate billet size derivation rules for each process. Constraint boundary layer: Defines the maximum allowable reduction rate, width-to-width ratio limit, and temperature compensation strategy for each process.

[0008] Furthermore, in the above-mentioned intelligent generation method for free forging process pass tables based on process templates and case databases, step S3, which involves calling a pre-set case database for reference or correction, specifically includes: S31: Based on the material grade and target size of the current task, retrieve historical process solutions with similarity higher than a preset threshold from the case database. The preset threshold is set by the constraint boundary layer of the standard process template matched in the process template library, and the preset threshold is set to ≥85%. S32: Extract the fire allocation ratio or key intermediate dimension coefficient from the historical process scheme, and use it as a reference or to correct the current fire division scheme and intermediate target dimensions.

[0009] Furthermore, in the above-mentioned intelligent generation method for free forging process pass table based on process templates and case databases, the pass iteration calculation in step S4 specifically includes: S41: For each process, first calculate the maximum allowable reduction for the current pass; S42: Determine the feed rate for the current pass by combining the anvil width dimension of the equipment and the forging penetration criterion; S43: Determine the flipping strategy based on the current process type; S44: Calculate the changes in height, width, and length after the current track ends; If the size evolution is detected to exceed the preset width-to-width ratio constraint or temperature boundary, a rollback mechanism is triggered to automatically adjust the parameters of the previous step or switch to a backup process strategy to continue iteration. The width-to-width ratio constraint and temperature boundary are defined from the constraint boundary layer of the matching standard process template.

[0010] Furthermore, in the above-mentioned intelligent generation method for free forging process pass table based on process templates and case databases, in step S5, the hierarchical structure is a three-layer structure of heat generation-process-pass, specifically including: Fire layer: Record the fire layer number, heating specifications, temperature range, and the start and end dimensions of the fire layer; Process layer: Records process sequence number, process name, associated fire sequence, and process target conditions; Pass layer: Records pass number, reduction amount, feed amount, rotation angle, pass end dimension, and process status indicator.

[0011] Furthermore, in the above-mentioned intelligent generation method for free forging process pass table based on process templates and case databases, in step S6, the cascade consistency verification specifically includes: S61: When it is detected that a user has modified the parameters of a certain course or performed an insert or delete course operation, the operation point is automatically locked; S62: Starting with the modified parameters, re-trigger the iterative algorithm in step S4 to recalculate the size evolution of all subsequent affected passages; S63: If the recalculation result violates the equipment load constraint or fails to converge to the target size, an immediate warning message will be output and a parameter adjustment range will be recommended.

[0012] Furthermore, in the above-mentioned intelligent generation method for free forging process pass tables based on process templates and case databases, step S7 is included after step S6: finite element simulation verification, which specifically includes: S71: Convert the reduction sequence, feed sequence and flip strategy in the generated process pass table into a preprocessed input file that can be recognized by the finite element simulation software. S72: Simulates the continuous hot deformation behavior of billets under multiple heating cycles; outputs the geometric accuracy, equivalent plastic strain distribution and forging load curve of the final forging to verify the reliability of the process scheme. S73: If the simulation verification fails, return to step S6 for manual correction; if the simulation verification passes, perform the solution entry operation.

[0013] Furthermore, in the above-mentioned intelligent generation method of free forging process pass table based on process templates and case database, in step S6, when the process pass table is entered into the database, an association index is established between the pass table and material records, equipment records and forging types, and a version management mechanism is adopted to record the time, operator and key parameter changes of each edit, so as to realize the traceable management of the process plan.

[0014] Furthermore, in the above-mentioned intelligent generation method for free forging process pass tables based on process templates and case databases, the free forging process design system based on B / S architecture includes a front-end interaction layer, a back-end logic layer, and a data storage layer. The front-end interaction layer includes a human-computer interaction interface for inputting and correcting parameters and a visual interface for displaying the process pass table. The back-end logic layer has the algorithm engine built-in. The data storage layer includes a material database, an equipment resource library, a process template library, and a historical case library. The material database is used to store the physical properties, thermodynamic parameters, and rheological stress models of materials. The equipment resource library is used to store the table size, maximum load, and impact frequency parameters of the equipment. The process template library is used to store the standard process templates. The historical case library is used to store verified process schemes and quality feedback data.

[0015] The intelligent generation method for free forging process pass table based on process templates and case database of the present invention has the following advantages and beneficial effects: (1) Significantly improve process design efficiency and reduce human error: This invention abandons the traditional manual experience estimation mode, and through structured collection of input parameters and conversion into calculation input vectors, combined with the built-in algorithm engine driven by process template, realizes the automated calculation from the division of fire number to the parameters of the pass number, replacing a large amount of manual repetitive calculation work and significantly improving design efficiency; at the same time, the standardized calculation logic effectively reduces the error rate of manual calculation and ensures the consistency of process output specifications. (2) Achieve structured accumulation and efficient reuse of process knowledge: This invention constructs a process template library and a historical case library, encapsulates mature process paths into standard process templates, and stores verified process solutions as historical cases. When designing new processes, templates can be quickly retrieved and similar cases can be searched through feature matching, transforming historical production experience into calculable and searchable digital assets, effectively solving the industry problem of the difficulty in accumulating, inheriting and reusing process knowledge. (3) Improve the rationality and practical feasibility of the process plan: In the stage of dividing the heat and establishing intermediate targets, the parameters are corrected by the heat allocation ratio and key intermediate dimension coefficients of historical cases, so that the process design is more in line with actual production experience; In the process of iterative calculation of the pass parameters, multiple dimensions such as equipment capacity, material deformation criteria, and width-to-width ratio constraints are integrated, and a rollback mechanism is set to ensure the rationality of parameter calculation; At the same time, through finite element simulation verification, problems such as insufficient geometric accuracy of forgings, uneven strain distribution, and excessive forging load are identified in advance, reducing on-site trial and error costs and material waste; (4) Forming a complete process design closed loop and knowledge iteration system: This invention constructs a complete process design closed loop of "data collection - template matching - parameter calculation - result display - interactive correction - simulation verification - scheme entry into the database". After the process scheme is verified, it is entered into the database to form new process knowledge. The process scheme is traceable through the version management mechanism, so that the process knowledge base can continuously iterate and evolve with actual application, providing richer reference for the enterprise's subsequent process design. (5) Adapting to enterprise-level digital applications and intelligent manufacturing needs: This invention is based on a B / S architecture system, which has cross-platform compatibility. At the same time, it builds four basic databases: materials, equipment, process templates, and historical cases, realizing integrated management of various process design data. It can provide stable and unified data support for enterprise-level large-scale and digital free forging process design, and promote the digital and intelligent transformation of the free forging industry. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only for further understanding of the embodiments of the present invention and constitute a part of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. In the drawings: Figure 1 This is a schematic diagram of the architecture of the free forging process design system based on the B / S architecture in an embodiment of the present invention; Figure 2 This is a schematic diagram of the material database management interface of the B / S architecture free forging process design system in an embodiment of the present invention; Figure 3 This is a schematic diagram of the management interface of the process template library of the B / S architecture free forging process design system in this embodiment of the invention; Figure 4 This is a schematic diagram of the parameter acquisition and input management interface in an embodiment of the present invention; Figure 5 This is a schematic diagram of the management interface for matching and retrieving corresponding standard process templates from the process template library in an embodiment of the present invention; Figure 6 This is a schematic diagram of the interface of the process pass table generated in an embodiment of the present invention. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below in conjunction with specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0018] like Figures 1 to 6 As shown, the intelligent generation method for free forging process pass tables based on process templates and case databases of the present invention is implemented based on a B / S architecture free forging process design system. The B / S architecture free forging process design system includes a front-end interaction layer, a back-end logic layer, and a data storage layer. The front-end interaction layer includes a human-computer interaction interface for inputting and correcting parameters and a visual interface for displaying the process pass tables. The back-end logic layer has a built-in algorithm engine. The data storage layer includes a material database, an equipment resource library, a process template library, and a historical case library. The material database stores the physical properties, thermodynamic parameters, and rheological stress models of the materials. The management interface of the material database is shown below. Figure 2 As shown; the equipment resource library is used to store the table size, maximum load, and impact frequency parameters of the equipment; the process template library is used to store the standard process templates; the management interface of the process template library is as follows. Figure 3 As shown; the historical case database is used to store verified process schemes and quality feedback data. The intelligent generation method for free forging process pass tables based on process templates and case databases of this invention includes the following steps: S1: Data Acquisition and Standardization: Parameters for free forging process design are acquired and input through the human-computer interaction interface in the front-end interaction layer of the B / S architecture free forging process design system. The acquired and input parameters include at least material property parameters, initial geometric parameters of the billet, target forging size parameters, and process constraints. These parameters are then converted into structured calculation input vectors. The parameter acquisition and input management interface of the free forging process design system is as follows: Figure 4 The meaning is as shown.

[0019] S2: Template Matching and Path Planning: Based on the process type and forging characteristics in the parameters, the system matches the corresponding standard process template from the process template library pre-set in the data storage layer of the B / S architecture free forging process design system. The standard process template defines the logic for the number of forging passes, the sequence of processes, and the deformation calculation rules for each process. The management interface for matching and retrieving the corresponding standard process template from the process template library is as follows: Figure 5 The meaning is as shown.

[0020] The defined structure of the standard process template includes at least three layers: Topology layer: Defines the logical order between firing cycles and the integrated process sequence within each firing cycle. The process sequence includes one or more of the following processes: pressing the handle, chamfering, upsetting, flattening, axial elongation, rounding, bottom cutting, and shaping. The computational logic layer defines the deformation criterion formula index and intermediate billet size derivation rules for each process. Constraint boundary layer: Defines the maximum allowable reduction rate, width-to-width ratio limit, and temperature compensation strategy for each process.

[0021] S3: Heat Division and Intermediate Target Establishment: Based on the matching standard process template, combined with heating regime parameters and allowable material deformation, the heat division scheme is automatically planned to determine the starting size, ending size and allowable process set of each heat. During this process, the B / S architecture free forging process design system calls historical similar case data pre-set in the case database of the data storage layer to refer to or correct the intermediate target size.

[0022] Using the case database for reference or correction specifically includes: S31: The B / S architecture free forging process design system searches the case database for historical process solutions with a similarity higher than a preset threshold based on the material grade and target size of the current task. The preset threshold is set by the constraint boundary layer of the standard process template matched in the process template library, and the similarity threshold is ≥85%. S32: Extract the fire allocation ratio or key intermediate dimension coefficient from the historical process scheme, and use it as a reference or to correct the current fire division scheme and intermediate target dimensions.

[0023] S4: Iterative Calculation of Pass Parameters: According to the determined set of processes, the algorithm engine in the back-end logic layer of the free forging process design system built into the B / S architecture is used to perform iterative calculation of each pass. Under the condition of meeting the equipment capacity and forming process constraints, the pass parameters, including the reduction amount, feed amount and flip angle, are derived one pass at a time, and the geometric dimensions of the billet are updated in real time according to the law of constant volume, until the termination dimension of the pass is reached.

[0024] The specific iteration calculation includes: S41: For each process, the B / S architecture free forging process design system first calculates the maximum allowable reduction for the current pass; S42: Determine the feed rate for the current pass by combining the anvil width dimension of the equipment and the forging penetration criterion; S43: Determine the flipping strategy based on the current process type; S44: Calculate the changes in height, width, and length after the current track ends; If the detected dimensional evolution exceeds the preset width-to-width ratio constraint or temperature boundary, the B / S architecture free forging process design system triggers a rollback mechanism, automatically adjusting the parameters of the previous step or switching to a backup process strategy to continue iteration. The width-to-width ratio constraint and temperature boundary are defined from the constraint boundary layer of the matching standard process template.

[0025] S5: Data Model Construction and Display: The discrete data generated by iterative calculations is reconstructed into a hierarchical process pass table, and displayed in the visualization interface of the front-end interactive layer of the B / S architecture free forging process design system. See the interface for the generated process pass table. Figure 6 The meaning is as shown.

[0026] The layered structure is a three-layer structure of fire-process-pass, specifically including: Fire layer: Record the fire layer number, heating specifications, temperature range, and the start and end dimensions of the fire layer; Process layer: Records process sequence number, process name, associated fire sequence, and process target conditions; Pass layer: Records pass number, reduction amount, feed amount, rotation angle, pass end dimension, and process status indicator.

[0027] S6: Interactive Correction and Solution Entry: Respond to user correction operations on the pass parameters through the human-computer interaction interface in the front-end interaction layer of the B / S architecture free forging process design system, and perform cascade consistency verification. After confirming that there are no errors, the final generated process pass table is associated with the case database for storage.

[0028] The cascaded consistency check specifically includes: S61: When the system detects that a user has modified the parameters of a certain pass or performed an insert or delete pass operation, the B / S architecture free forging process design system automatically locks the operation point. S62: Starting with the modified parameters, re-trigger the iterative algorithm in step S4 to recalculate the size evolution of all subsequent affected passages; S63: If the recalculation result violates the equipment load constraints or fails to converge to the target size, the B / S architecture free forging process design system will immediately output a warning message and recommend a parameter adjustment range.

[0029] S7: Finite element simulation verification: S71: The B / S architecture free forging process design system converts the reduction sequence, feed sequence and flipping strategy in the generated process pass table into a preprocessed input file that can be recognized by finite element simulation software. S72: Call the finite element simulation software's simulation solver to simulate the continuous hot deformation behavior of the billet under multiple heating cycles; output the geometric accuracy, equivalent plastic strain distribution, and forging load curve of the final forging to verify the reliability of the process scheme. S73: If the simulation verification fails, return to step S6 for manual correction; if the simulation verification passes, perform the solution entry operation.

[0030] Furthermore, in the intelligent generation method of free forging process pass table based on process template and case database of the present invention, in step S6, when the process pass table is entered into the database, an association index is established between the pass table and the material record, equipment record and forging type. The association index is constructed based on the core features of free forging process (material grade, forging type, equipment model), and a version management mechanism is adopted to record the time of each edit, the operator and key changes of pass parameters (reduction amount, feed amount, and heat division), so as to realize the traceability management of process plan.

[0031] Example The following uses the forging of 45 steel cylindrical billets into plate-shaped billets as a practical application scenario to explain in detail the intelligent generation method of the free forging process pass table based on process templates and case databases of the present invention, including the following steps: S1: Data Acquisition and Standardization The system uses a front-end visual human-computer interaction interface to collect all input parameters for this free forging process design, completing the conversion of unstructured parameters into structured calculation input vectors. The specific parameters are as follows: Material properties: 45 steel (carbon structural steel), density 7850 kg / m³ 3 The forging temperature range is 1200~900℃, and the maximum reduction rate is about 25%. Initial geometric parameters of the billet: diameter φ1120mm × height 2445mm, cylindrical billet; Target forging dimensions: 170mm thickness × 1270mm width × 9800mm length, plate blank, thickness and width tolerance ±15mm, length tolerance ±45mm; Process constraints: First heating temperature 1220℃, holding time 14h; Second heating temperature 1200℃, holding time 8h; Maximum reduction in the second heating ≤ 20% of the current billet height.

[0032] S2: Template Matching and Path Planning The system extracts core features from the computational input vector: the process type is "cylindrical billet → slab billet", the material is 45 steel, and the firing cycle constraint is 2 firing cycles. Based on the feature matching algorithm, it accurately matches and retrieves the standard process template for cylindrical / polygonal → slab (2 firing cycles) from the process template library. The three-layer definition structure of this template is as follows: Topological structure layer: The first firing process sequence is (pressing the clamp handle → chamfering → upsetting → flattening the square → cutting the riser), and the second firing process sequence is (axial elongation → repeated shaping). The computational logic layer calls the deformation criterion formula (volume invariance law) of the upsetting process to derive the intermediate billet size, calls the width expansion formula of the drawing process to calculate the width expansion amount of each pass, and determines the derivation rule of the intermediate billet size of each process as "roughing first and then finishing, step by step"; Constrained boundary layer: The single hammer reduction in the second firing is ≤20%, and the anvil width ratio is 0.6~0.8; large reduction is required when the temperature is >1100℃, medium reduction is required when the temperature is 900℃~1000℃, and reheating is required when the temperature is <850℃.

[0033] S3: Fire sequence classification and intermediate target establishment Based on the matching standard process template for shaft forgings, the system combines heating regime parameters (preset hot transport steel ingot and hot material return furnace insulation parameters) with the allowable deformation degree of 45CrMo steel to automatically plan the heat division scheme, determine the starting size, ending size and allowable process set of each heat, and call similar case data in the historical case library to correct the intermediate target size.

[0034] The specific implementation process of S3 is as follows: Based on the material grade (45CrMo) and target size (170mm×1270mm×9800mm) of the current task, the system searches the historical case database for historical process solutions with a similarity of more than 85%, and finally matches 3 similar cases (all of which are 45CrMo material, rectangular cross-section shaft forgings, and the billet size is ≥88% similar to the target size). Extract the heat distribution ratio (first heat mainly for rough forging and deformation, second heat mainly for finish forging and shaping) and key intermediate dimensional coefficients (upsetting dimensional coefficient and drawing process dimensional evolution coefficient) from three sets of historical process schemes. Use this information to revise the current heat distribution scheme and intermediate target dimensions, ultimately determining: First firing: Starting dimensions φ1120mm×2445mm, ending dimensions 1300mm×230mm (rectangular cross-section), allowable process set includes pressing the handle, chamfering, upsetting, flattening, and removing excess material; Second firing: starting size 1300mm×230mm (rectangular cross section), ending size 170mm×1270mm×9800mm, the allowed process set is axial elongation and shaping.

[0035] S4: Iterative Calculation of Trace Parameters The system, based on a defined set of processes for each heat treatment, uses its built-in algorithm engine to perform iterative calculations for each heat treatment. Under the constraints of equipment capacity and forming process, it derives the reduction, feed rate, and flipping angle pass by pass, and updates the billet's geometry in real time according to the law of constant volume, until the final dimension of that heat treatment is reached. If the dimensional evolution is detected to exceed preset constraints, a rollback mechanism is triggered to adjust the parameters before continuing the iteration. The specific calculation process is as follows: First firing: Each process executes steps S41-S44 without any dimensional over-constraints, thus eliminating the need to trigger a rollback mechanism. The core calculation results are as follows: Pressing clamp process: Pressing amount = initial diameter of billet × 30% = 1120 × 30% = 336mm. Based on the equipment capacity, the pressing amount is determined to be 320mm. The feed rate is determined to be 550mm based on the anvil width (800mm) and the forging penetration criterion. Flipping strategy: After pressing one pass, flip it 90°, offset it by half, and then press the next pass; then flip it 45 degrees and 90 degrees respectively to turn the pliers handle into an octagon; Dimensions after calculation of each pass: The diameter of the pliers handle is φ800mm, the length of the pliers handle is 700mm, the excess pliers handle is cut off, the dimensions meet the preset requirements, and there are no constraints or violations; Beveling process: Pressing amount = current billet diameter (1120mm) × 16% = 179.2mm, the pressing amount is determined to be 180mm, the feed amount is 550mm, the flipping angles are 90°, 90°, 90°, 45°, 90°, 90°, 90°, half anvil offset, anvil overlap amount is 550mm, the final beveling dimension is φ940mm, which meets the constraints; Upsetting process: Using an upper and lower flat anvil, the clamp handle is placed in a special mold, and the chamfered part is upset in a similar way to the upper and lower flat anvil without flipping. The final upset size is φ1730mm, and the volume is reduced compared to the corresponding stage of the initial blank. Flattening process: upper flat anvil, lower flat anvil, pressing amount = current billet diameter (1730mm) × 20% = 346mm, determine the pressing amount as 340mm, feed amount 450mm, flip angle 90°, half anvil offset, anvil overlap 350mm, continuously cycle until the thickness and width dimensions reach reasonable values, so that the final flattened square size is 1300mm × 230mm (rectangular cross section), which meets the first fire termination dimension requirements; Residual material removal process: There is no reduction or feeding amount, only the removal operation is performed to ensure that all residual material at the riser and sprue ends is removed, leaving only the forging body, and the dimensions are in compliance with regulations.

[0036] Second fire: Axial drawing process: Change the mold, the width of the upper and lower anvils is 600mm, the maximum allowable reduction in the current pass = the current billet thickness (230mm) × 20% = 46mm, combined with the heating temperature (1200℃, no temperature compensation required), determine the single hammer reduction as 45mm, and the feed rate as 300mm. Flipping strategy: Lengthen along the axial direction, flip 90° after each pressing, stagger the anvil by half, to ensure uniform lengthening; Dimensional evolution calculated per pass: After each pass of drawing, the height, width and length of the billet are updated in real time. The accuracy of the dimensions is verified based on the law of constant volume. After multiple passes of drawing, the billet size reaches ~170mm×~1270mm×L. Shaping process: Maximum allowable reduction = current billet thickness (175mm) × 20% = 35mm, determine reduction of 10-15mm (finishing), feed amount of 300mm, flip angle of 90°, repeat shaping 10 times, final size reaches 170mm±15mm×1270mm±15mm×L, gradually approaching the target size of 170mm×1270mm×9800mm; Constraint verification: Throughout the entire second firing iteration, the temperature remained within the forging temperature range and did not exceed the constraint boundary, with no rollback mechanism triggered.

[0037] S5: Data Model Building and Presentation The system reconstructs the discrete pass data generated by iterative calculation into a standardized process pass table according to a three-layer structure of fire number-process-pass number, and displays it on the front-end visualization interface. The specific recording content and specifications of the three-layer structure are as follows: Heat treatment layer: Record relevant information for two heat treatments. The first heat treatment is hot-transferring steel ingots at 1220℃ for 14 hours, with a temperature range of 1200-900℃, starting dimensions of φ1120mm×2445mm, and ending dimensions of 1300mm×230mm×L. The second heat treatment is hot material returning to the furnace for heat preservation at 1200℃ for 8 hours, with starting dimensions of 1300mm×230mm×L and ending dimensions of 170mm×1270mm×9800mm. Process layer: Record 7 processes. Numbers 1-5 belong to the first heat (pressing the clamp handle, chamfering, upsetting, flattening, and removing excess material), and numbers 6-7 belong to the second heat (axial elongation and shaping). Record the heat sequence and process target conditions for each process (such as the clamp handle target φ800mm, the chamfering target φ940, etc.). Pass layer: Records the specific pass information for each process, including pass number, reduction amount, feed amount, rotation angle, pass end dimension and process status label (qualified / pending verification). The process status label for each pass is "qualified".

[0038] S6: Interactive Correction and Solution Input Process engineers can verify the generated process pass schedule and process card parameters through the system's visual interface. Regarding the question of "how much material needs to be removed" in the first heat removal process, they can manually add the parameter "remove all remaining material, leaving only the forging body." Once the system detects this modification, it automatically locks the operation point and triggers a cascading consistency check. Lock the parameter modification points for the process of removing excess material, and prohibit the simultaneous modification of parameters for other unrelated processes; Starting with the modified residual material removal parameters, the iterative algorithm in S4 is retried to recalculate the dimensions after the residual material is removed in the first fire. It is confirmed that after all the residual material is removed, the billet dimensions can still meet the initial dimension requirements of the second fire, and there are no abnormalities in the dimension evolution of each pass in the subsequent second fire. The recalculation results did not violate the equipment load constraints and converged to the target size. The system did not output any warning messages, and the verification passed.

[0039] After verification, the process engineers confirm that there are no errors. The system then links the final generated process pass table and process card to the historical case library for storage. At the same time, it establishes an association index between the pass table and the material record (45 steel), equipment record (800mm anvil width, 60000kN maximum load free forging hammer), and forging type (plate shape). The index is built based on material grade, forging type, and equipment model, and adopts a version management mechanism to record the time of this edit, the operator, and key changes in pass parameters (addition of parameters for removing excess material), so as to achieve traceable management of the process plan.

[0040] S7: Finite Element Simulation Verification To verify the reliability of the generated process pass schedule and process card, the system performs finite element simulation verification steps: The pressing amount sequence, feed amount sequence and flipping strategy in the generated process pass table are converted into a preprocessed input file that can be recognized by the finite element simulation software (DEFORM), imported into the simulation software and meshed and boundary condition set (consistent with the actual forging equipment and temperature environment). The simulation solver of the finite element simulation software is called to simulate the continuous hot deformation behavior of the billet under two heating cycles, and output the geometric accuracy, equivalent plastic strain distribution and forging load curve of the final forging. Simulation results analysis: The final forging geometry is 172mm×1268mm×9795mm, which meets the target dimensional tolerance requirements (thickness and width tolerance ±15mm, length tolerance ±45mm); the equivalent plastic strain distribution is uniform, with no local strain concentration; the forging load curve is stable, with a maximum load of 43619kN, which does not exceed the maximum load of the equipment (60000kN), and there are no load abrupt changes, verifying the reliability of the process scheme; Defect detection: No forging defects such as folds, cracks, or internal porosity were detected in the full-process simulation.

[0041] The simulation verification results were satisfactory, and the process plan is feasible for actual production. The system will execute the final plan storage operation, link the simulation results with the process pass table, and automatically generate the process pass table for this free forging process.

[0042] It should be noted that, unless otherwise expressly specified and limited, the term "connection" or its synonyms should be interpreted broadly in this document. For example, "connection" can be a fixed connection or a detachable connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal communication of two elements or the interaction between two elements. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances. Furthermore, expressions such as "first" and "second" are merely used to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Meanwhile, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. In addition, the terms "front," "rear," "left," "right," "upper," and "lower" in this document refer to the placement states shown in the accompanying drawings.

[0043] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for intelligently generating a free forging process pass list based on process templates and a case database, characterized in that, The method is implemented based on a B / S architecture free forging process design system. The intelligent generation method of the free forging process pass table based on process templates and case database includes the following steps: S1: Data Acquisition and Standardization: Parameters for free forging process design are acquired and input through a human-computer interaction interface. The acquired and input parameters include at least material property parameters, initial geometric parameters of the billet, target forging size parameters, and process constraints. The parameters are then converted into structured calculation input vectors. S2: Template matching and path planning: Based on the process type and forging characteristics in the parameters, match the corresponding standard process template from the preset process template library. The standard process template defines the logic of the number of firing cycles, the order of the processes, and the deformation calculation rules for each process. S3: Heat Division and Intermediate Target Establishment: Based on the matching standard process template, combined with heating regime parameters and allowable material deformation, the heat division scheme is automatically planned to determine the starting size, ending size and allowable process set of each heat. During this process, historical similar case data from the preset case database is called to refer to or correct the intermediate target size. S4: Iterative calculation of pass parameters: According to the determined set of processes, the built-in algorithm engine performs iterative calculation of each pass. Under the condition of meeting the equipment capacity and forming process constraints, the reduction amount, feed amount and flip angle are derived for each pass, and the geometric dimensions of the billet are updated in real time according to the law of constant volume until the termination dimension of the pass is reached. S5: Data Model Construction and Display: Reconstruct the discrete data generated by iterative calculation into a hierarchical process pass table and display it in a visualization interface; S6: Interactive Correction and Solution Entry: Respond to user correction operations on process pass parameters and perform cascaded consistency checks. After confirming that there are no errors, the final generated process pass table is associated with the case database for storage.

2. The intelligent generation method for free forging process pass table based on process templates and case database according to claim 1, characterized in that, In step S2, the defined structure of the standard process template includes: Topology layer: Defines the logical order between firing cycles and the integrated process sequence within each firing cycle. The process sequence includes one or more of the following processes: pressing the handle, chamfering, upsetting, flattening, axial elongation, rounding, bottom cutting, and shaping. The computational logic layer defines the deformation criterion formula index and intermediate billet size derivation rules for each process. Constraint boundary layer: Defines the maximum allowable reduction rate, width-to-width ratio limit, and temperature compensation strategy for each process.

3. The intelligent generation method for free forging process pass table based on process templates and case database according to claim 2, characterized in that, In step S3, calling the pre-built case database for reference or correction specifically includes: S31: Based on the material grade and target size of the current task, retrieve historical process solutions with similarity higher than a preset threshold from the case database. The preset threshold is set by the constraint boundary layer of the standard process template matched in the process template library, and the preset threshold is set to ≥85%. S32: Extract the fire allocation ratio or key intermediate dimension coefficient from the historical process scheme, and use it as a reference or to correct the current fire division scheme and intermediate target dimensions.

4. The intelligent generation method for free forging process pass table based on process templates and case database according to claim 3, characterized in that, In step S4, the iteration calculation specifically includes: S41: For each process, calculate the maximum allowable reduction for the current pass; S42: Determine the feed rate for the current pass by combining the anvil width dimension of the equipment and the forging penetration criterion; S43: Determine the flipping strategy based on the current process type; S44: Calculate the changes in height, width, and length after the current track ends; If the dimensional evolution exceeds the preset width-to-width ratio constraint or temperature boundary, a rollback mechanism is triggered to automatically adjust the parameters of the previous step or switch to a backup process strategy to continue iteration. The width-to-width ratio constraint and temperature boundary are defined from the constraint boundary layer of the matching standard process template.

5. The intelligent generation method for free forging process pass table based on process templates and case database according to claim 4, characterized in that, In step S5, the layered structure is a three-layer structure of fire-process-pass, specifically including: Fire layer: Record the fire layer number, heating specifications, temperature range, and the start and end dimensions of the fire layer; Process layer: Records process sequence number, process name, associated fire sequence, and process target conditions; Pass layer: Records pass number, reduction amount, feed amount, rotation angle, pass end dimension, and process status indicator.

6. The intelligent generation method for free forging process pass table based on process templates and case database according to claim 5, characterized in that, In step S6, the cascaded consistency check specifically includes: S61: When it is detected that a user has modified the parameters of a certain course or performed an insert or delete course operation, the operation point is automatically locked; S62: Starting with the modified parameters, re-trigger the iterative algorithm in step S4 to recalculate the size evolution of all subsequent affected passages; S63: If the recalculation result violates the equipment load constraint or fails to converge to the target size, an immediate warning message will be output and a parameter adjustment range will be recommended.

7. The intelligent generation method for free forging process pass table based on process templates and case database according to claim 6, characterized in that, Step S6 is followed by step S7: finite element simulation verification, which specifically includes: S71: Convert the reduction sequence, feed sequence and flip strategy in the generated process pass table into a preprocessed input file that can be recognized by the finite element simulation software. S72: Simulates the continuous hot deformation behavior of billets under multiple heating cycles; outputs the geometric accuracy, equivalent plastic strain distribution and forging load curve of the final forging to verify the reliability of the process scheme. S73: If the simulation verification fails, return to step S6 for manual correction; if the simulation verification passes, perform the solution entry operation.

8. The intelligent generation method for free forging process pass table based on process templates and case database according to claim 1, characterized in that, In step S6, when the process pass list is entered into the database, an association index is established between the process pass list and the material records, equipment records, and forging types. A version management mechanism is adopted to record the time of each edit, the operator, and changes to key parameters, so as to achieve traceable management of the process plan.

9. The intelligent generation method for free forging process pass table based on process templates and case database according to any one of claims 1 to 8, characterized in that, The B / S architecture free forging process design system includes a front-end interaction layer, a back-end logic layer, and a data storage layer. The front-end interaction layer includes a human-computer interaction interface for inputting and correcting parameters and a visual interface for displaying the process pass table. The back-end logic layer has the algorithm engine built-in. The data storage layer includes a material database, an equipment resource library, a process template library, and a historical case library. The material database stores the physical properties, thermodynamic parameters, and rheological stress models of materials. The equipment resource library stores the table size, maximum load, and impact frequency parameters of the equipment. The process template library stores the standard process templates. The historical case library stores verified process schemes and quality feedback data.

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