Radial Forging Pass Schedule for Complex Shape and Temperature Control
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Solution Overview
Problem
Current automatic pass schedule calculation methods for radial forging are limited to simple geometries like steel bars and fail to optimize forging results for complex shapes such as offset shafts, as they do not adequately account for temperature distribution, shape change, and material flow during the forging process.
Innovation Solution
A method using a pass schedule calculation program that combines stitch plan calculation software with the finite element method to optimize temperature and shape change distribution across the workpiece cross-section, considering multiple influencing parameters like tool geometry, pressing force, and material properties, allowing for the calculation of a detailed pass plan that ensures precise forming of complex geometries like railway axles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automatic pass schedule calculation is used for radial forging, then productivity is improved, but manufacturing precision deteriorates for complex geometries
Solution Approach 1:
The workpiece cross-section is divided into multiple finite elements (nodes and integration points) to enable localized temperature and strain calculation. This segmentation allows the pass schedule calculation program to account for non-uniform temperature distribution and material flow across different regions, thereby maintaining manufacturing precision while using automated calculation.
Solution Approach 2:
The method implements iterative feedback by calculating temperature distribution and strain distribution based on material flow, then using these results to adjust and optimize the pass schedule. This closed-loop approach ensures that temperature thresholds are not exceeded and manufacturing precision is maintained throughout the forging process.
2Manufacturing precision
If finite element method is used to calculate temperature distribution, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The pass schedule calculation program performs preliminary calculations of temperature distribution and strain distribution before the actual forging process. By pre-calculating these parameters based on the defined pass schedule and material flow assumptions, the method avoids time-consuming finite element analysis during production while maintaining sufficient precision for process optimization.
Solution Approach 2:
The method changes the calculation approach by using simplified thermal and mechanical models within the pass schedule calculation program rather than full finite element analysis. This parameter change allows rapid calculation of temperature and strain distributions while maintaining adequate precision for process planning and optimization.
3Adaptability or versatility
If complex geometries are forged, then adaptability is improved, but manufacturing precision deteriorates due to material flow complexity
Solution Approach 1:
The method applies local quality by calculating and optimizing material flow, temperature distribution, and strain distribution for each specific region of the workpiece cross-section. Different zones (e.g., journal areas, transition areas, central areas) are analyzed individually to ensure precise deformation control tailored to local geometric requirements, enabling accurate forging of complex stepped shaft geometries.
Data Source
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AI summary
The invention relates to a method for automatically calculating the forging schedule for radial forging of long products made from metallic workpieces, in particular steel, in 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 long product, wherein start parameters for the radial forging process are entered into a forging schedule calculation program and target parameters for the radial forging process are defined, and the forging schedule calculation program calculates a forging schedule or a forging sequence based on these start and target parameters, wherein the forging schedule calculation program takes into account the temperature development and the temperature distribution over the cross-section of the long product as well as the deformation during radial forging.Furthermore, the invention relates to a control and/or regulating unit as well as a radial forging machine for carrying out the method according to the invention.