Computer-aided forging-die design for two-dimensional cross-sectional components

In the closed-die forging process which allows flash into the flash gap of the finisher die, forging design starting with the machined section geometry is the first procedure and is influenced by the nature of the metal to be processed, and the capabilities and limitations of the forging process. This paper describes some developments of an automatic forging-die design system for two-dimensional components and discusses several applications of the system. According to the design sequences, empirical guidelines which are concerned with the design of the forging and the finisher die, obtained from an extensive literature review, were first compiled in a structured and systematic form as design rules and database, some of them being introduced in the paper. Two-dimensional cross-sections (axisymmetric and plane-strain sections) can be dealt with by this system, being automatically decomposed. recognized and modified for the design of the forging and the finisher die. Accordingly, forging design which considers the geometric features of the section of the machined part can be carried out. The results obtained from the system developed at authors' laboratory have been compared with those from other sources, the results corresponding well, apart from a few minor differences. The design results of the system were investigated according to forging type, forging material and flat-web location.