An Automated Process Planning and Die Design System for Quasi-Axisymmetric Cold Forging Products

This paper deals with an automated computer-aided process planning and die design system with which a designer can determine operation sequences even after only a little experience in process planning and die design of quasi-axisymmetric cold forging products by multistage former working. The approach is based on knowledge-based rules, and a process knowledge base consisting of design rules is built. Knowledge for the system is formulated from plasticity theories, empirical results and empirical knowledge of field experts. Programs for the system have been written in AutoLISP for AutoCAD with a personal computer. An attempt is made to link programs incorporating a number of expert design rules with the process variables obtained by commercial FEM software, DEFORM and ANSYS, to form a useful package. The system is composed of three main modules and five submodules. The process planning and die design module considers several factors, such as the complexities of preform geometry, punch and die profiles, specifications of available multiformers, and the availability of standard parts. The system uses 2D geometry recognition and is integrated with the technology of process planning, die design, and CAE analysis. The standardisation of die parts for wheel bolts requiring a cold forging process is described. The system developed makes it possible to design and manufacture quasi-axisymmetric cold forging products more efficiently.