Forging Press Secondary Drive Layout for Lower-Energy Forming
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Solution Overview
Problem
Existing forging processes are not energy-efficient, particularly in performing various types of forging such as open-die forging, die forging, and finishing, as they require high energy consumption and large masses for primary and secondary drives.
Innovation Solution
A forging press design where the secondary drive is supported by an assembly loaded with primary forming forces, allowing for energy-efficient operation by reducing the mass and volume of components moved during secondary forming processes, and optimizing the coordination between primary and secondary drives to minimize energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional forging press uses a single primary drive for all forming operations, then it can perform various forging processes (open-die forging, die forging, finishing), but it requires high energy consumption and moves large masses unnecessarily
Solution Approach 1:
The upper saddle is divided into two independent parts: a primary saddle driven by the primary drive for main forming operations, and a secondary saddle driven by a secondary drive for finishing operations. This segmentation allows each drive to be optimized for its specific function, with the secondary drive moving only the lighter secondary saddle rather than the entire upper saddle assembly, thereby reducing energy consumption while maintaining versatility across different forging processes
Solution Approach 2:
The system dynamically switches between primary and secondary drives depending on the forging operation required. The secondary drive is selectively engaged for finishing operations where smaller forces and faster stroke rates are needed, while the primary drive handles main forming operations. This dynamic allocation of drive functions optimizes energy usage by matching drive capacity to actual operational requirements
2Force
If the secondary drive moves the entire upper saddle assembly, then it can apply secondary forming forces, but it requires large volumes of oil and high energy input
Solution Approach 1:
The upper saddle is segmented into a primary saddle and a secondary saddle that are independently driven. The secondary drive only needs to move the secondary saddle (with smaller mass) rather than the entire upper saddle assembly. This reduces the volume of hydraulic oil that must be moved and decreases the energy input required for secondary forming operations, while still delivering the necessary secondary forming forces to the workpiece
Solution Approach 2:
The secondary drive system is designed with local quality optimized for finishing operations: a smaller, lighter secondary saddle with reduced mass moment of inertia, allowing for faster stroke rates and lower energy consumption. The primary saddle retains the full mass and structural properties needed for main forming operations. Each saddle is locally optimized for its specific functional requirements
Data Source
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AI summary
The invention relates to a forging press with a forging press frame comprising an upper die, a lower die, a primary drive, which acts relative to the forging press frame, for applying primary shaping forces onto a workpiece between the upper die and the lower die, and a secondary drive for applying secondary shaping forces onto the workpiece. The invention also relates to a method for forging a workpiece in a forging press with an upper die, a lower die, and a primary drive by means of which a primary movement that has a shaping effect is driven between the upper die and the lower die. The workpiece is also shaped by a secondary movement of a secondary die in addition to the shaping process produced by the primary movement, said secondary movement having a shaping effect and being driven by a secondary drive. According to the invention, different types of forging processes, such as free-form forging, drop forging, and/or sizing, can be carried out in an energy-saving manner if the secondary drive is supported on assemblies which are loaded by the primary drive with primary shaping forces in the direction of the workpiece or if the secondary drive drives a secondary die and the secondary die is moved independently of the primary drive assemblies driving the primary movement for the secondary movement of the secondary die.