Forging Flaw Prediction Using Strain Rate and Face Angle
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Solution Overview
Problem
Existing analysis techniques for predicting forging flaws become ineffective when mesh reconstruction occurs due to plastic deformation, requiring sequential observation of the forging process and relying on human experience for determining flaw timings and locations.
Innovation Solution
A forging flaw determination system that includes a forging analysis device and a forging flaw determination device. The system generates a forged article model for multiple forging processes, calculates strain rates based on analysis meshes, and predicts the presence or absence of flaws using logistic regression analysis with strain rate and face angle as explanatory variables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If numerical simulation based on finite element method is used to predict flaw locations, then flaw prediction capability is improved, but when mesh reconstruction occurs due to plastic deformation, the flaw shape becomes invisible requiring sequential observation
Solution Approach 1:
The patent calculates strain rates and face angles at each forging process stage in advance, before mesh reconstruction occurs. By pre-calculating these parameters and storing them, the system avoids the need for sequential observation after mesh reconstruction, thus resolving the time loss issue while maintaining prediction accuracy
Solution Approach 2:
The patent creates a virtual copy of the forging process through numerical simulation, where strain rates and face angles are calculated in the simulated environment. This virtual copying allows flaw prediction without needing to physically observe the actual forging process sequentially, eliminating time loss while preserving prediction capability
2Measurement precision
If sequential observation of forging process is performed to find flaws, then flaw detection capability is improved, but determination depends on worker experience restricting efficiency
Solution Approach 1:
The patent replaces the mechanical system of human observation and experience-based judgment with an automated computational system. The second controller automatically calculates strain rates, face angles, and determines flaw occurrence using predetermined thresholds, substituting human workers' sequential observation with algorithm-based automated determination, thus improving efficiency while maintaining detection accuracy
Solution Approach 2:
The system performs self-determination of flaw occurrence by automatically comparing calculated strain rates and face angles against predetermined thresholds. The second controller independently makes determination without requiring human intervention or experience-based judgment, enabling automated flaw detection that improves productivity while maintaining consistent accuracy
3Loss of time
If analysis technique is used to predict flaws, then advance prediction is improved, but mesh reconstruction causes flaw shape to become invisible
Solution Approach 1:
The patent focuses on calculating strain rates and face angles specifically at locations where flaws are likely to occur, rather than analyzing the entire forged article model. By concentrating computational resources on critical local areas, the system maintains advance prediction capability while preserving flaw shape information in regions of interest despite mesh reconstruction elsewhere
Data Source
AI summary
A forging flaw determination system includes a forging analysis device and a forging flaw determination device. The forging analysis device is configured to generate a forged article model in a plurality of forging processes for forging, and includes a first controller. The first controller is configured to calculate a strain rate based on an analysis mesh for the forged article model. The forging flaw determination device is configured to predict, based on the forged article model, the presence or absence of a flaw phenomenon when a forged article is formed in each forging process for the forging, and includes a second controller. The second controller is configured to determine the presence or absence of the flaw phenomenon based on the strain rate and a face angle between faces of adjacent analysis meshes.