Analysis for the Automation of Small Batch Manufacturing Using Open Die Forging

Abstract

Open die forging is a long established process which can be used to produce a wide range of shapes. Its characteristics features in relationship to other types of forming processes are that it requires low forming loads and only a small range of simple tools to make a wide variety of shapes. Whilst the process is generally associated with the production of large forgings, an automated version could be attractive for small batch manufacturing of low weight forgings. Such a system could compete effectively against machining process. This paper examines the process of pressing small size pans by open die forging, reviews existing literature and presents an upper bound based solution for single step and incremental open die forging. The validity of the theoretical analysis is assessed by comparison with experiments and found to be ill a good agreement.