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

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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.

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Acknowledgements

The authors wish to express their sincere appreciation to Marc Payelleville from the lycée Marie Curie of Nogent-sur-Oise for the realisation of the experimental protocols. Moreover, we would like to thank MANOIR INDUSTRIES and the REGION GRAND EST for their financial support in this research project.

Funding

This research project is supported by MANOIR INDUSTRIES.

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Authors and Affiliations

  1. Arts et Metiers Institute of Technology, Université de Lorraine, LCFC, HESAM Université, F-57070, Metz, France

    Jean-François Mull, Camille Durand, Cyrille Baudouin & Régis Bigot

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  1. Jean-François Mull
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  2. Camille Durand
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  3. Cyrille Baudouin
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  4. Régis Bigot
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Correspondence to Jean-François Mull.

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Mull, JF., Durand, C., Baudouin, C. et al. A new tailored solution to predict blow efficiency and energy consumption of hammer-forging machines. Int J Adv Manuf Technol 111, 1941–1954 (2020). https://doi.org/10.1007/s00170-020-06237-2

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