Knowledge-based Design Method of Forging Dies based on the Stereotypes of Die Structures and the Functions of Forming Surfaces

Abstract

The die design of forged products greatly affects the quality, cost, and delivery of cold- and warm-forged products. However, such design is often not easy even for experienced engineers because extensive knowledge and experience of plastic forming, forging, blanking, and punching are required. This paper proposes a general forging die design method termed GeneDie on the basis of the basic die structure and the forming surfaces configuration which are introduced as basic concepts for the support of simple but general die design. The basic die structure is the relative positional inter-relationship among the components of forging dies and is used to represent the structure of forging dies simply. Meanwhile, the forming surfaces configuration is the correspondence between functions allocated to the surfaces of forging dies and the surfaces of a forged product and used to represent the shapes of forming dies concisely. Die design plans are generated by exhaustively assuming a basic die structure and a forming surfaces configuration that satisfy design requirements and then verifying design constraints regarding formability, workability, and economy. An experimental knowledge base is implemented adopting the GeneDie method and applied to a forging process plan for an electrical connector. Experimental results show that die design plans that are functionally equivalent to those of an experienced engineer are included in the plans generated for all forming steps of the forging process plan.