Recent developments on high precision forging of aluminum and steel

Abstract

Precision forming is a suitable means to meet the increasing demands for the cost-effective prediction of net-shape or near-net-shape parts in large quantities. This article demonstrates the different procedures applied to the precision forming of parts dependent on the specific critical aspects of the process. Examples are given for the geometrical and thermal layout of the forging process, the influence of material behavior on the forged part and a procedure for the compensation of the die deflection. A suitable layout of the forging sequences is the precondition for further optimization steps of the forging parameters. CAE techniques provide state-of-the-art simulation and reproducible manufacturing tools for precision forging. Computer based engineering development systems integrate design and simulation tools to optimize the forging process. The application of these tools increases the basic understanding for the net-shape production of complex shaped parts. Beneath the optimization of the forging process layout the attainable precision also depends on the accuracy of toolmaking and process control. During the forging process the control of forging load and thermal conditions, including thermal treatment, is necessary to establish reproducible conditions for net-shape manufacturing.