Quantification of press elasticity in the forging of three-dimensional complex shapes

Abstract

This paper presents an improved approach to characterize press elastic behaviour and to quantify the effect of press elasticity in the forging of three-dimensional (3D) complex shapes. Using a stiffness matrix formulation, the overall press elasticity is characterized by press elastic deformation and initial clearances of the press guideway. The effect of press elasticity in forging is evaluated by implementing the press stiffness matrix formulation into the 3D forging simulation using a user subroutine. An industrial-based 3D blade forging case study was carried out to assess the robustness and efficiency of this approach in the forging of 3D complex shapes. Compared with cases without press elasticity, the results show that the press elasticity has less effect on forging force requirements, material deformation, and stress and strain distributions. However, the effect of press elasticity is more apparent on the dimensional and shape accuracy of the forged blade with the initial guideway clearance as a major source for dimensional errors compared with the press elastic deformation. The case study also shows that this approach can be easily implemented for evaluating press tool-related effects in forging simulation and design.

Validation of a purely elastic model and a finite element model for a screw press

“…A loading of a machine in a specific direction can be realized through two mains methods: either we use the machine in its normal functioning mode and a stroke is exploited as load generator [6,7] or external device like hydraulic cylinder placed on the press table can be used to apply load directly to the ram [8]. Otherwise some studies propose to perform FE simulation to avoid experimental errors and simplify mechanical loading [9]. Then, experimentally or numerically, deformations obtained allows to calculate press stiffness.…”

Optimal Process Conditions for the Manufacture of Aluminum Alloy Bicycle Pedals

“…A hybrid force-position control method was proposed and performed on a novel serial-parallel forging manipulator. Lu and Ou [2] used an improved approach to characterize press elastic behavior and to quantify the effect of press elasticity to forge complex three-dimensional (3D) shapes. Wang et al [3] improved the two-stage extrusion process and related die designs of a forging company that currently manufactures a support shaft by using the traditional method.…”