Abstract
The general step reduction and enlargement (GeneSteR + E) method and the general forging die design (GeneDie) method can exhaustively generate forging processes and dies for non-axisymmetric forged products. However, the variation of generated plans are limited, potentially excluding optimal solutions. This paper proposes an optimization support method that generates alternative design plans for non-axisymmetric forged products. The proposed method generates various die design plans according to various shapes of a workpiece and relative positions of the forged product and workpiece to dies. The shape of an initial work material is generated by resizing the shape in an original process plan while keeping the same volume as planned, and the parting lines of dies are defined by rotating the forged product around its center of gravity. The positions of the workpiece are generated by distributing the workpiece around its center of gravity. The shape of a forged product is modified so that undercut constraints are satisfied on the premise of subsequent blanking or punching processes. A large number of design candidates are evaluated by a finite element method analysis tool using a robotic process automation (RPA) tool. An experimental design knowledge base and RPA workflows were developed and applied to the forging dies of automotive parts. The experimental results show that the proposed method can generate alternative forging dies including those nearly equivalent those designed by an experienced engineer but in less time.
R. Okamoto — The author is currently working for Hitachi Ltd.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Notes
- 1.
The forged parts are then formed into additional shapes such as gears as automotive parts.
References
Lange, K., Du, G.: A formal approach to designing forming sequences for cold forging. Trans. of the NAMRI/SME, pp. 17–22 (1989)
Numthong, C., Butdee, S.: The knowledge based system for forging process design based on case-based reasoning and finite element method. Asian Int. J. Sci. Technol. Prod. Manufacturing Eng. 5(2), 45–54 (2012)
Takata, O., Nakanishi, K., Yamazaki, T.: Forming-sequence design expert system for multistage cold forging: Forest-d. In: Proceedings of Pacific Rim International Conference on Artificial Intelligence 90, pp. 101–113 (1990)
Ohashi, T., Imamura, S., Shimazu, T., Motomura, M.: Computer-aided die design for axis-symmetric cold forging products by feature elimination. J. Material Processing Technol. 137, 138–144 (2003)
Kumar, S., Singh, R.: A low cost knowledge base system framework for progressive die design. J. Mater. Process. Technol. 153, 958–964 (2004)
Takata, O., Mure, Y., Nakashima, Y., Ogawa, M., Umeda, M., Nagasawa, I.: Knowledge-based system for process planning and die configuration design in cold forging. In: Proceedings of the 8th International Conference on Technology of Plasticity, p. 8 (2005)
Xuewen, C., Siyu, Z., Jun, C., Xueyu, R.: Research of knowledge-based hammer forging design support system. Int. J. Advanced Manufacturing Technol. 27, 25–32 (2005)
Lee, R.-S., Hsu, Q.-C., Su, S.-L.: Development of a parametric computer-aided die design system for cold forging. J. Mater. Process. Technol. 91, 80–89 (1999)
Umeda, M., Mure, Y.: Knowledge management strategy and tactics for forging die design support. In: Abreu, S., Seipel, D. (eds.), Applications of Declarative Programming and Knowledge Management, Vol. 6547 of Lecture Notes in Computer Science, Springer-Verlag New York Inc, pp. 188–204 (2011). https://doi.org/10.1007/978-3-642-20589-7_12
Kim, H.S., Im, Y.T.: An expert system for cold forging process design based on a depth-first search. J. Mater. Process. Technol. 95, 262–274 (1999)
Umeda, M., Mure, Y., Katamine, K., Matsunaga, K.: General Step Reduction and Enlargement Method for Knowledge-Based Process Planning of Totally Non-Axisymmetric Forged Products with Blanking and Punch Proceedings of the 13th International Conference on the Technology of Plasticity (ICTP2021), pp. 1161–1171 (2021)
Matunaga, K., Umeda, M., Mure, Y., Katamine, K.: Knowledge-based design method of forging dies based on the stereotypes of die structures and the functions of forming surfaces. In: Proceedings of the 18th International Conference Metal Forming, pp. 475–482 (2020)
Umeda, M., Katamine, K., Nagasawa, I., Hashimoto, M., Takata, O.: Multi-threading inside prolog for knowledge-based enterprise applications. In: Umeda, M., Wolf, A., Bartenstein, O., Geske, U., Seipel, D., Takata, O. (eds.) INAP 2005. LNCS (LNAI), vol. 4369, pp. 200–214. Springer, Heidelberg (2006). https://doi.org/10.1007/11963578_16
Mure, Y., Higashi, D., Higashi, N.: Development of forming techniques based on sequential forging method for waterproof USB Type-C connectors (in Japanese). In: Proceedings of Research Report of Kagoshima Prefectural Institute of Industrial Technology, pp. 8–9 (2021)
Acknowledgement
This research was supported by TOGO CO., Ltd., Kagoshima Prefecture.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2024 The Author(s), under exclusive license to Springer Nature Switzerland AG
About this paper
Cite this paper
Okamoto, R., Umeda, M., Mure, Y., Katamine, K., Imanaga, K. (2024). Optimization Support Method for Cold and Warm Forging Dies of Non-axisymmetrical Forged Products. In: Mocellin, K., Bouchard, PO., Bigot, R., Balan, T. (eds) Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity. ICTP 2023. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-41023-9_1
Download citation
DOI: https://doi.org/10.1007/978-3-031-41023-9_1
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-031-41022-2
Online ISBN: 978-3-031-41023-9
eBook Packages: EngineeringEngineering (R0)