Computer modelling of tool loads and press/tool deflections in multistage forging

Abstract A mathematical model of the deflections arising during forging in a multistage press provides the basis for the development of a computer package which can be used to predict the dimensional changes in workpieces occurring at each stage, due to a change at any one stage and individual tool loads and total press load for any given set of conditions. The program can be used to speed up tool setting times by enabling the correct shut-heights for each forming stage to be determined without trial and error. It can be used also to investigate the effects of changes (either deliberate or unintentional) in process conditions such as: lubrication, billet volume or hardness, on the dimensions of the finish forged component. The program has been validated by comparing its output with the results of experiments comprising: single-stage, two-stage and three-stage forging undertaken on a vertical crank press.