Abstract
Cold extrusion and forging processes require significant improvements in productivity to ensure the continued competitiveness of press manufacturers and users. Current average productivity rates in high volume, high tonnage forming operations can be as low as 60%, while the lost production capacity is mainly due to equipment failures and unreliable processes control. A group of companies representing press manufacturers and users collaborated within the National Center of Manufacturing Sciences to diagnose common problems and recommend solutions. Major findings presented in this paper pertain to identifying and eliminating root causes of lost production in an automated facility running multiple high tonnage mechanical presses. A multicomputer system developed as a part of the project and example results that prove the feasibility of predictive monitoring, diagnosis and control are presented.
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