Process Design and Tooling Configuration for Precision Forging of High Performance Components

Precision forging is a production process which uses forming technology for manufacturing near-net shaped, highly loaded components. In comparison to conventional forming and machining production processes, an improvement in material savings and a significant shortening of the process chain can be obtained. Subsequent to the forming and the integrated heat-treatment process, often only a final hard-finishing of specific functional surfaces with minimum cutting volumes is necessary. The increased demands on dimensional and geometric accuracy from precision forgings result in increased requirements from the applied forging tools, the forming machines as well as from the specific design and control of the process. Therefore the Finite Element Analysis (FEA) is an appropriate simulation tool. Aims of the current research are the development of strategies for comprehensive process design and shrinking correction as well as the enhancement of the machines and tooling technologies for precision forging. Precise tool design requires a detailed knowledge about material specific heat balance resulting in a process and tool related heat transfer.