Abstract
The study deals with the energy-saving process of hot open die elongation forging of heavy steel forgings on an 80 MN industrial hydraulic forging press. Three innovative energy-saving power supply solutions useful for industrial hydraulic forging presses were analyzsed. The energy-saving power supply of hydraulic forging presses consists in reducing electricity consumption by the electric motor driving the pumps, reducing the noise emitted by pumps and reducing leaks in hydraulic piston cylinders. The predicted forging force as a function of heavy steel forging heights for various deformation temperatures and strain rates was determined. A simulation model of the 80 MN hydraulic forging press is presented, which is useful for determining the time-varying parameters during the forging process. An energy-saving control for the hydraulic forging press based on the forging process parameters’ prediction has been developed. Real-time model predictive control (MPC) was developed based on multiple inputs multiple outputs (MIMO), and global predictive control (GPC). The GPC has been implemented in the control system of an 80 MN industrial hydraulic forging press. The main advantage of this control system is the repeatability of the forging process and minimization of the size deviation of heavy large steel forgings
Highlights
Along with the development of the energy industry and the growing power of power engineering devices, the demand for large-sized hot-forged products has increased, which include turbine shafts, rotors for wind, and gas power generators
The forecast of the Forging Industry Association (FIA) regarding the steady increase in demand for forgings used in the power engineering and oil industries was confirmed at the 20th International Forgemasters Meeting (IFM’2017) in Austria
An important contribution of this study is to present how to go from predicting the parameters of the hot open die forging process to the control parameters of the industrial hydraulic forging press to produce good quality heavy large steel forgings, leading to a reduction in electricity consumption, a reduction in gas consumption, and a reduction in noise emitted by pumping systems, as well as savings in working fluid
Summary
Along with the development of the energy industry and the growing power of power engineering devices, the demand for large-sized hot-forged products has increased, which include turbine shafts (water, gas, steam), rotors for wind, and gas power generators. An important contribution of this study is to present how to go from predicting the parameters of the hot open die forging process to the control parameters of the industrial hydraulic forging press to produce good quality heavy large steel forgings, leading to a reduction in electricity consumption, a reduction in gas consumption, and a reduction in noise emitted by pumping systems, as well as savings in working fluid (water). Such solutions can be used in different steel production processes (SMP). This research article provides knowledge of the process of forging heavy and large forgings, which is usually limited to specialists in industrial practice
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