Radial Forging Pass Schedule for Complex Geometry Tolerances
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Solution Overview
Problem
Existing software for automated pass schedule calculation in radial forging is limited to simple geometries like forging bar steel and fails to account for complex geometries such as offset shafts, particularly in maintaining precise tolerances and optimizing temperature and deformation distributions during forging.
Innovation Solution
A method and system that utilizes a pass schedule calculation program combined with the finite element method to optimize temperature and deformation distributions, considering multiple influencing parameters, including tool geometry, material flow, and heat generation, to calculate an optimized forging sequence for complex geometries like railway axles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing pass schedule calculation software is used, then simple geometries like bar steel can be forged, but complex geometries such as offset shafts cannot be processed with precise tolerances
Solution Approach 1:
The patent applies local quality by dividing the complex workpiece into discrete cross-sections and calculating deformation and temperature distributions specifically for each cross-section. This allows the software to handle complex geometries with varying tolerances at different locations, rather than applying uniform calculations throughout the entire workpiece.
Solution Approach 2:
The patent transitions from one-dimensional bar steel calculations to three-dimensional cross-sectional analysis. By considering deformation and temperature distributions across the entire cross-section area, the software can accurately process complex geometries with varying shapes and tolerances in multiple dimensions.
2Manufacturing precision
If finite element method is used to calculate temperature and deformation distributions, then accurate results are obtained, but calculation time increases significantly
Solution Approach 1:
The patent extracts the essential calculation elements from the full finite element method, focusing only on the critical parameters needed for pass schedule optimization. By calculating deformation and temperature distributions specifically at cross-sections rather than performing complete FEM analysis, the software achieves sufficient accuracy with reduced computation time.
Solution Approach 2:
The patent applies partial action by performing calculations only where necessary - specifically at cross-sections of the workpiece - rather than conducting exhaustive finite element analysis throughout the entire workpiece volume. This selective approach provides sufficient accuracy for manufacturing decisions while significantly reducing calculation time.
3Reliability
If detailed temperature and deformation distribution calculations are performed, then forging quality is optimized, but computational complexity and cost increase
Solution Approach 1:
The patent focuses computational resources on calculating temperature and deformation distributions at specific cross-sections where quality is most critical, rather than performing exhaustive calculations throughout the entire workpiece. This localized approach optimizes forging quality at key locations while managing computational complexity.
4Manufacturing precision
If pass schedule calculation considers material flow and heat generation, then complex geometries can be forged with optimized microstructure, but software complexity increases
Solution Approach 1:
The patent performs preliminary calculations of material flow and heat generation during the pass schedule planning phase. By predicting temperature and deformation distributions before actual forging, the software can optimize the pass schedule to achieve desired microstructures without requiring complex real-time control systems during manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the secure, dependable, and reproducible forging of complex geometries by maintaining precise tolerances and optimizing material flow, temperature, and deformation distributions, reducing material waste, and ensuring no threshold values are exceeded, resulting in a microstructure optimized over the length and cross-section of the forged product.
Implementation Method 1
the pass schedule calculation program takes into account the temperature variation and the temperature distribution over the cross section of the long product
Implementation Method 2
the calculation of the temperature distribution and deformation distribution using the finite element method is time consuming
Data Source
AI summary
Radial forging of long products made of metal workpieces in a radial forging machine uses at least four forging tools arranged around the circumference of the workpiece, which are set up and adapted to simultaneously carry out the forging operation. An automatic pass schedule calculation includes entering start parameters for the radial forging process into a pass schedule calculation program and defining target parameters for the radial forging process. The pass schedule calculation program calculates a pass schedule or a forging sequence based on these start and target parameters. The pass schedule calculation program determines a temperature variation and the temperature distribution over the cross section of the long product and takes into account the change in shape during radial forging.