Online Visualization during Open Die Forging and Optimization of Pass Schedules**

Abstract

By using fast calculation models, the equivalent strain, temperature, and average austenitic grain size in the center of an ingot can be determined. When used in an online process monitor by coupling with a measuring system, these models are fast enough to visualize the current state of an ingot during forging. Based on a model forging process, the use of the program is demonstrated. Comparing results from metallography of the forged billet with the calculated grain size, a good agreement could be achieved (deviation of 6–24%). Even before the forging process, the presented automatic pass schedule optimization can be applied. Through this, a process could be optimized concerning a high homogeneous equivalent strain and a low number of strokes. As result of the optimization, an increasing grain size and temperature could be observed. Thus it could be useful to change other process parameters, like lowering the furnace temperature.

Application of a Fast Calculation Model for the Process Monitoring of Open Die Forging Processes

“…As realised during the project, FAST is of a great help evaluating recorded process data to analyse and further improve forging processes. Another promising application it the processing of pass schedules to allow an approximation of the equivalent strain and grain size distribution [19].…”