A new tailored solution to predict blow efficiency and energy consumption of hammer-forging machines

Abstract

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

Development and research of the press operating mechanism, made in the form of the wedge-joint mechanism with a curving wedge for separation operations

“…We find from the speed plan that = • . (11) The resulting formula completely coincides with the previously obtained result (8).…”

“…(5) To determine the angular velocity of the joint 2, we differentiate formula, reducing it to the form = ⁄ and then we obtain: (8) in time, we find the acceleration of the slide:…”

“…A number of scientists have made a significant contribution to the creation and subsequent development of scientific foundations for the development of equipment and technologies for the implementation of waste-free methods for separating bar sections [4][5][6][7][8]. Mechanical presses abroad are produced by such countries as: USA, Germany, Japan, England, etc., companies: National, Eumuco, Haserclever, Erie, etc.…”

Application of 3D Scanning as an Indirect Method to Analyze and Eliminate Errors on the Manufactured Yoke-Type Forgings Forged in SMED Device on Modernized Crank Press

“…Die-forging processes for large series of products use, for example, in the automotive industry are usually realized on mechanical or hydraulic presses [ 1 ]. As opposed to open-die and semi-free die forging, which makes it possible to punch large size ingots and produce “large forgings” in a small series [ 2 ], e.g., for the aircraft industry, which are produced on aggregates with high pressures and energies [ 3 , 4 ], such as steam-air hammers, wedge presses, etc. [ 5 , 6 , 7 ].…”

Development And Research Of The Press Operating Mechanism, Made In The Form Of The Wedge-Joint Mechanism With A Curving Wedge For Separation Operations

“…A number of scientists have made a significant contribution to the creation and subsequent development of scientific foundations for the development of equipment and technologies for the implementation of waste-free methods for separating bar sections [4][5][6][7][8]. Mechanical presses abroad are produced by such countries as: USA, Germany, Japan, England, etc., companies: National, Eumuco, Haserclever, Erie, etc.…”