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The article presents the results of a complex analysis referring to the possibilities of applying different types of construction of forging dies used on a hydraulic hammer Lasco HO-U 160 in order to select the optimal solution in the aspect of obtaining the required dimension-shape accuracy. The analysis involved the use of the numerical simulation software FORGE 3.0 NxT. 12 different variants were analyzed, of both different tool constructions and detail arrangements on the die (in a quadruple and sixfold system). The effect of the forces as well as the way of material flow and degree of the forging tool seat’s filling were verified. The most ergonomic and technologically justified detail arrangement on the die was described. The results of the numerical simulation analyses were presented with the indication of the pros and cons of the particular solutions. The selected solution of the forging tool construction, implemented in a mass production, was especially discussed to verify of obtained FEM results and improvement actual technology.

The article presents a comprehensive review of key issues and challenges related to enhancing the durability of hot forging tools. It discusses modern strategies aimed at increasing tool life, including modifications to tool materials, heat treatment, surface engineering, tool and die design, die geometry, tribological conditions, and lubrication. The review is based on extensive literature data, including recent publications and the authors’ own research, which has been implemented under industrial conditions at the modern forging facility in Forge Plant “Glinik” (Poland). The study introduces original design and technological solutions, such as an innovative concept for manufacturing forging dies from alloy structural steels with welded impressions, replacing traditional hot-work tool steel dies. It also proposes a zonal hardfacing approach, which involves applying welds with different chemical compositions to specific surface zones of the die impressions, selected according to the dominant wear mechanisms in each zone. General guidelines for selecting hardfacing material compositions are also provided. Additionally, the article presents technological processes for die production and regeneration. The importance and application of computer simulations of forging processes are emphasized, particularly in predicting wear mechanisms and intensity, as well as in optimizing tool and forging geometry.

The engine main shaft forgings have high requirements for product consistency and reliability, which are difficult to be guaranteed by traditional manual free forging. On the basis of the already-in-place machinery, technical optimization was done in order to realize intelligent forging of the engine main shaft forgings. A rail trailer, holding robot, inspection robot, and expert system were installed as well as other hardware and software. Additionally, the procedure and specifications for robot intelligent free forging were revised. Based on the artificial neural network (ANN) model, an optimization model and a prediction model were created, and the process parameters can be controlled during forging. The verification result shows that the intelligent free forging production line can achieve real-time control of the shaft forging process, and obtain the forgings whose shape, size, microstructure, performance and consistency meet the requirements. With the help of this production line, free forging can be produced more quickly and efficiently, which is crucial for realizing the automation, digitization, and intelligence of shaft forging free forging.

This paper provides a review of the methods developed over the years for reducing working forces for the precision metal forming processes. Precision forging normally involves completely, or near completely closed cavity dies with no or minimal draft, making features on the extremities difficult to fill and requiring high loads. Means to minimise load, in order to enhance tool life, or reduce press capacity are crucial to the success of precision forging processes. The main concentration of this study is on design features which can be incorporated in tooling and/or workpiece in order to assist in minimisation of forging load while achieving complete die filling. The load reduction methods are presented using examples mainly of precision gear forging, which is representative of the precision forging of other axisymmetric components with complex peripheral shape. The methods reviewed are divided into the categories of (i) billet design, (ii) tool design and (iii) process design. Their effects on forging load reduction for precision forging, along with the authors’ opinions as to the benefits, drawbacks and applicability of each, are presented.

The long shaft forgings in the roll forging forming process and the rigidity of the metal will change due to temperature. When the roller forging clamping device holds the forging piece on one side, the shaft forging piece will be bent due to self-weight, and the height of the other side of the forging piece will be changed, which will affect the operation of forging automation. In this paper, through the statistical analysis of sample data, the relationship between forging temperature and height deviation value is fitted, which solves the problem of how the change in the height of long shaft forgings affects robot handling in the automation process of roll forging. The stability of the forging automation is improved, while the method reduces the investment cost of the production line by using models instead of expensive vision hardware.

To enhance the forming quality of the forging and minimize the forging cost in the concave radial forging process, this article examines the influence of process parameters (radial reduction ∆h, rotation angle β, friction coefficient μ) on the forging process through numerical simulation. A multi-objective optimization method is employed to balance the objective functions (strain homogeneity E, forging load F). First, sample points for different combinations of process parameters were obtained using a central composite experimental design. Then, a mathematical model between the process parameters and the objective function was established using the response surface method, which underwent variance analysis and sensitivity analysis. Finally, the optimal process parameter combination was determined based on the NSGA-II algorithm and satisfaction function. The optimization results were verified by finite element simulations. The optimized process combination: ∆h = 0.25 mm, β = 21.68°, μ = 0.05. The corresponding E and F are 0.241367 and 577.029, respectively. Compared with the initial process, the standard deviation of the overall strain was reduced by 14.25%, and the forging load was reduced by 1.76%. The results indicate that the quality of the forgings was significantly improved while the forging cost was reduced to some extent.

An advanced process of mandrel forging and necking (MFN) was proposed for a hollow shaft with an inner stepped hole. The conventional mandrel forging process with an equal-diameter mandrel was used to form the outer stepped preform, and then the preform was formed into the hollow shaft with an inner stepped hole using the MFN process. A numerical simulation model was established to study the effect of the pressing reduction and the rotation angle on the MFN process. A preforming design method based on the isometric radius difference was given according to the principle of the equal volume, and the parameter relationships between the outer and inner stepped shapes were clarified. The experimental deformation laws of the MFN process were consistent with those obtained by the simulation. The MFN process and its preforming design method provide a new free forging approach for large hollow forgings with inner stepped holes.

To address incomplete die filling, high cracking tendency, and severe die wear in the conventional forging of AISI-410 martensitic stainless steel U-shaped forgings, an optimized billet volume pre-allocation strategy was proposed. Two improved forging schemes for the U-shaped forgings were designed: the Arc Concave Flattening Scheme (adding arc-shaped concave features to the flattening die for corner volume compensation) and Preformed Volume Allocation Scheme (incorporating a preforming step for strategic volume pre-allocation at ends and corners). Finite Element Analysis employing the Oyane damage model and Archard wear model was employed to simulate and optimize the forging process. The optimal scheme was applied to production trials. The results demonstrated that the Preformed Volume Allocation Scheme significantly improved the geometric compatibility between the billets and the final forging die cavity. As a result, the billet’s temperature, strain, and equivalent stress uniformity increased, reducing cracking tendency. Moreover, the rise in the mitigated temperature and stress concentration resulted in reduced final forging die wear. Production trials confirmed a qualified rate of ~96% (34% higher than the Original Scheme). The final forging die service life reached 300 pieces per refurbishment cycle, showing a 50% improvement. This work provides theoretical and practical guidance for optimizing the forging processes of complex martensitic stainless steel components.

Flashless forging is classified as a precise metal forming technology. The main advantages of this technology are the reduction of the flash allowance and the shortening of the manufacturing time by eliminating the flash trimming operation. The article presents the process of one-step forging of a stepped shaft made of aluminum with the use of split dies. The process was carried out in cold and hot metal-forming conditions. The forging process was analyzed numerically using the Simufact Forming 15.0 software. The geometrical parameters of the obtained product were analyzed, and the distribution of effective strain, temperature, and the standardized cracking criterion was determined. The process force parameters were also determined. Numerical tests were verified in real conditions with the use of a specially designed device for forging in vertical split dies. Comparison of hot and cold forging in vertical split dies is presented. The comparative analysis results have demonstrated that the hot forging process has more advantages than the cold forging process. The hot forging process ensures higher accuracy of forged parts.

Due to the influence of temperature and other factors in the forming of forgings, the shape of the forging fringe is often challenging to control and predict, which restricts the operation of forging automation. In this paper, the forging position is detected by the vision means, which is conductive to identify whether the production process is normal or not to avoid the loss caused by the interruption of the production unit. Meanwhile, for the forging temperature changes on visual recognition, the relationship curve between forging temperature and exposure time is determined by statistical method, so that the temperature of the forging regulate the visual camera exposure time to improve the accuracy of visual recognition.