This paper presents an approach for a holistic simulation of forging processes considering the interactions between forging press, tooling system and forging process. It can be used in coupled simulations and will enable industrial users in forging industry to do simulation-aided tool optimizations in the design stage of newly developed forging dies. The final aim is to reduce the time-consumin...

The purpose of this study is to develop a forging process of automotive parts that satisfies the deformation characteristics. The analyses of temperature variation and deformation behavior of the material are important to obtain the optimal forging products. The hot compression test was carried out to know formability at high temperature. In order to define the optimum forging conditions includ...

The purpose of this research is to achieve the optimal parameters for producing forged aluminium alloy 7075 aircraft door bracket by using finite element modelling (FEM) with commercial DEFORM-3D V6.1 and physical simulations with plasticine and Plexiglas dies. Also, forging speed has been examined as the main factor for controlling to produce a part without any defects. The results of Physical...

The purpose of this research is to analyze the forging of bevel gears based on conventional forging method with material number 1.7131 with finite element method by means of SUPER FORGE software and to compare it with experimental cold orbital forging results.After doing simulation of conventional forging and obtaining press tonnage due to orbital forging method with DEFORM software, orbital fo...

Preform design in forging processes is an important aspect for improving the forging quality and decreasing the production cost. The objective of this paper is to obtain an optimal perform shape in the consideration of the influence of the metal flow deformation in closed die forging process. Finite element method based DEFORMTM 3D software in conjunction with Taguchi method has been used to si...

This research introduces an advanced forging method to produce the door frame of the wind turbine tower. The advantage of the new forging method is the increase of raw material utilization ratio and the energy saving. In the conventional method, the door frame is hot forged with a hydraulic press and machined out lots of material because of the big difference between forging shape and final mac...

Cooperating with heavy forging press, the heavy-duty forging manipulator is used for handling the workpiece during the free-forging process. Therefore, the size accuracy of the forgings is related to the dynamics performance of the forging manipulator. This paper aims to study the dynamic performance of DDS heavy-duty forging manipulator. The kinematics model is firstly built to predict the tra...

There are a wide range of physical defects which occur during metal forming processes. These defects, which may occur on the surface or be internal, are undesirable not only because of the surface appearance, but because they may adversely affect the strength, formability and other manufacturing characteristics of the material. Some physical defects in metal forming processes such as rolling an...

There are several method for forming bulk material, such as forging, rolling and extrusion. Every of these methods have advantages and dis-advantages of their selves. Forging process is one of the most common of them that include a die, press and in some case heater with controlling system, and has a special place in automotive, military and aerospace industries due uniformity of the final prod...