Radial Forging Pass Schedule for Complex Pipe Geometry
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Solution Overview
Problem
Current automatic pass schedule calculation methods for radial forging machines are limited to simple geometries and do not account for complex parameters such as temperature distribution and shape change, particularly in pipe forging, which affects the reproducibility and optimization of forging results.
Innovation Solution
A method using a pass schedule calculation program that incorporates tool geometry, pressing force, temperature development, and shape change distribution, combined with the finite element method, to calculate an optimized pass schedule for radial forging of pipes, allowing for complex geometry formation and adherence to material-specific parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automatic pass schedule calculation software is used for radial forging, then the automation of the forging process is improved, but the software is only able to calculate simple geometries such as steel bars and cannot handle complex pipe geometries
Solution Approach 1:
The patent extends the pass schedule calculation software from handling only simple bar geometries to complex pipe geometries by incorporating additional geometric parameters (inner diameter, outer diameter, wall thickness) and material flow patterns specific to tubular workpieces. This parameter expansion enables the same automated software to handle both simple and complex geometries.
2Measurement precision
If the finite element method is used to calculate temperature distribution and strain distribution, then the precision of temperature and strain analysis is improved, but the calculation becomes time-consuming and costly requiring technologically trained personnel
Solution Approach 1:
The patent segments the analysis into two parts: using simplified calculation methods for routine pass schedule determination, and applying the finite element method only when detailed temperature and strain distribution analysis is specifically required. This segmentation allows most calculations to be performed quickly while maintaining the option for high-precision analysis when needed.
Solution Approach 2:
The patent introduces an intermediary simplified calculation model that provides approximate temperature and strain distribution results quickly. This intermediary model serves as a first-level analysis tool, with the finite element method available as a second-level detailed analysis tool when higher precision is required, thus reducing overall calculation time while maintaining necessary accuracy.
3Adaptability or versatility
If tube forging is carried out using a mandrel as abutment, then the forming of complex tube geometries is enabled, but the process lacks the characteristics of reversible forging found in open-die forging
Solution Approach 1:
The patent employs multiple forging tools arranged around the circumference of the tube blank that can apply forces in different directions and sequences. This dynamic tool arrangement enables reversible forging actions on tubular workpieces, allowing the material to be worked in alternating directions similar to open-die forging, while still maintaining the ability to form complex tube geometries.
Data Source
AI summary
The invention relates to a method for automatically calculating the forging plan for radial forging of long products made from metallic workpieces, particularly 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 over at least a partial length of the workpiece and/or the tube, wherein start parameters for the radial forging process are entered into a forging plan calculation program and target parameters for the radial forging process are defined, and the forging plan calculation program calculates a forging plan or a forging sequence based on these start and target parameters. The invention further relates to a control unit and/or regulation unit as well as a radial forging machine for carrying out the method according to the invention.