Fullering process is a type of open die forging. In this research, elongation and maximum sideways spread in final shape of a billet after the first blow of a fullering process are predicted by designing a back propagation multilayer perceptron neural network. Several experiments are conducted using lead as the model material. Billets with three different square cross-sections are used in these...

Efficient cutting design is essential to reduce the costs of production in the open die forging industry. This article discusses a slab cutting design problem that occurs when parallel piped items are cut from raw material steel slabs with varying widths and lengths to meet a volume requirement. The problem is modeled as a two-dimensional cutting stock problem or bin packing problem with size-c...

In an effort to maximize grain growth of open-die forged 6061 aluminum alloy parts, samples from three of Weber Metals’s suppliers (Hidal Co-Almex USA Inc., TST Inc., and Vista Metals Corp.; to be called Supplier H, Supplier T, Supplier V respectively) were cut into cylinders with diameters of 0.75 ̋ and heights of 2 ̋, and put through a simulated forging process and heat treatment. It is possibl...

Internal die cooling during forging can reduce thermal loads, counteracting surface softening, plastic deformation and abrasive wear. Additive manufacturing has great potential for producing complex geometries of the internal channels. In this study, hybrid dies were developed combining conventional processes laser powder bed fusion (L-PBF) achieving conformal A characterisation used hot-work t...

Electro Discharge Machining (EDM) is a very efficient machining process widely used in manufacturing components of complicated geometry. Based on its nature, i.e. material removal by electric discharge, the process induces thermal stresses that in turn result in generation of wide spread micro-cracks on the surface of the machined part. In this paper the influence of EDM characteristic paramete...

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...

Geometrical error due to twist springback is one of major defects found in the near net or net shape part. It becomes more critical for complex part such as an Autonomous Underwater Vehicle (AUV) propeller blade. In this study, twist springback was quantified by comparing the blade and the die profiles obtained from commercial optical technique namely Alicona system. The results show a differen...