Energy saving has become a real issue in process management and has led to the analysis of the energy consumption of forging machines, for the purpose of optimization. This study focuses on the amount of energy lost due to machine behaviour during the forming process. A spring-mass-damping model of the machine and tools system is associated with a billet model to describe hammer-forming operations only during the forging phase. The model parameters are identified with experimental measurements of process variables during a stroke, providing parameters specifically adapted to the machine-tools system. Then, model predictions are validated by the experimental upsetting of steel and aluminium billets. The model accurately predicts forging process variables for consecutive blows with different materials. The decrease in process efficiency and the evolution from inelastic to elastic blows after several strokes on the same billet are also predicted by the model. This methodology provides a new, tailored solution that enables forging manufacturers to predict the forging energy consumption of their own machines. The approach developed in this work concerns gravity drop hammers but is also transferable to other energy-driven machines.Jean-François Mulljeanfrancois.mull@ens am.eu
The increasing use of superalloys in the industry brings new issues to forging manufacturers concerning Finite Element analysis of the forming process. Once we consider high performing materials, significant differences can occur between numerical and experimental results. The lack of knowledge about materials and thermal exchanges explains a part of these differences but it has been shown that the machine behavior has a significant impact on the forging process. Press modelling is a way to quantify the energy dissipated in the machine structure and improve simulations. This study is a first step in the screw press modelling. Starting from an approximation of the press geometries, a purely static elastic (PSE) model is developed and a numerical simulation considering only uprights is performed. Uprights stiffness predictions from the PSE model and the FE simulation are compared and the PSE model is validated. Then, the press is approximated by a portal frame and FE simulation is realized to determined uprights stiffness by considering links effects and bending behaviors in the structure. Comparison with experimental results validates the approximation.
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