Offset Shaft Forging Schedule Calculation for Temperature Control
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Solution Overview
Problem
Current automatic pass schedule calculation software is limited to simple geometries like steel bars and fails to optimize forging results for complex geometries such as offset shafts, particularly in radial forging machines, where temperature distribution and material flow are critical for achieving precise tolerances and minimizing material waste.
Innovation Solution
A method using a pass schedule calculation program that integrates stitch plan calculation software with the finite element method to account for tool geometry, pressing force, temperature development, and shape change distribution, enabling the calculation of optimized forging sequences for complex geometries like railway axles, ensuring precise temperature and deformation control across the workpiece cross-section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If pass schedule calculation software is used for simple geometries like steel bars, then the automation and reproducibility of the forging process are improved, but the software cannot handle complex geometries such as offset shafts
Solution Approach 1:
The patent extends the calculation software's capabilities by incorporating additional parameters specific to complex geometries, including temperature distribution across the cross-section, strain distribution, material flow patterns, and geometric characteristics of offset shafts. This allows the same software platform to handle both simple and complex geometries by adapting the calculation parameters.
Solution Approach 2:
The patent divides the complex geometry into manageable segments or zones, calculating temperature and strain distribution across different cross-sectional areas. This segmentation approach allows the software to process complex shapes by breaking them down into smaller computational units while maintaining overall automation.
2Manufacturing precision
If temperature distribution and strain distribution are calculated using the finite element method, then the accuracy of forging process optimization is improved, but the calculation time and cost increase significantly
Solution Approach 1:
The patent implements a hierarchical calculation approach where a simplified pass schedule calculation is performed first to obtain preliminary results, and then finite element analysis is applied selectively to critical zones or only when necessary to verify and optimize specific parameters. This partial application of FEM reduces overall calculation time while maintaining accuracy where most needed.
Solution Approach 2:
The patent performs preliminary pass schedule calculations using simplified models to establish a baseline forging sequence before applying more computationally intensive finite element analysis. This preliminary action allows the system to identify promising candidates for optimization and focus detailed FEM analysis only on those cases, significantly reducing total computation time.
3Manufacturing precision
If the pass schedule calculation program considers multiple parameters including temperature development and material flow, then the quality of forged pieces is improved, but the complexity of the calculation program increases
Solution Approach 1:
The patent designs the pass schedule calculation program as a multi-functional system that can handle various parameters (geometry, temperature, strain, material flow) within a unified computational framework. This universal approach allows the same program structure to process multiple parameters simultaneously without requiring separate specialized programs for each parameter, thereby managing complexity while maintaining comprehensive analysis capability.
Data Source
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AI summary
The invention relates to a method for automatically calculating the forging schedule for forging, in particular radial forging, of stepped shafts made of metallic workpieces, especially steel, in a forging machine, preferably a radial forging machine, with at least four forging tools arranged around the circumference of the workpiece, which are set up and adapted to simultaneously perform the forging operation at least over a partial length of the workpiece and/or the stepped shaft, wherein start parameters for the forging process, preferably radial forging, are entered into a forging schedule calculation program and target parameters for the forging process, preferably radial forging, are defined, and the forging schedule calculation program calculates a forging schedule or a forging sequence based on these start and target parameters.Furthermore, the invention relates to a control and/or regulating unit as well as a forging machine for carrying out the method according to the invention.