Development of Forging Process Optimization System Using Wear Model

摘要

We describe how we developed a system called "YOURS-PRO", which is designed to optimize the forging process. YOURS-PRO is a two-dimensional die design system for the front wheel hub, a forged-axle component. This system can be used in designing the best preform processes to ensure long die life. We first identified the object to be optimized and the required system specification by both FTA (failure tree analysis) and QFD (quality function deployment) methods. Then, we developed a new equation for calculating the amount of forging die wear. The new equation was derived from the equation proposed by Felder and Montagut, which takes the effect of contact time into account. The wear distribution on the surface of forging dies was measured. Then, the constant moduli were determined by applying the experimental results to the basic formula. We developed a new algorithm for predicting wear distribution based on the FEM results. We applied the wear prediction system to optimize the preform shape design. The geometrical relationship between the preform and finisher die designs was obtained. Our new automatic die design system "YOURS-PRO" was completed, together with the new FEM module for quality assurance.