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A Combined Numerical and Experimental Investigation on Deterministic Deviations in Hot Forging Processes

机译：热锻造过程中确定性偏差的组合数值和实验研究

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In hot forging processes, geometry of the formed workpieces deviate from the desired target geometry, due to complex interactions between tools and billets which result in inhomogeneous temperature and stress fields. The resulting deviation can only be mapped insufficiently by using numerical simulation which makes it difficult to be considered when designing the tool. Therefore, the development of forging tools requires an iterative adaptation process through a large number of revisions in the tool geometry, which escalates the resulting costs. To compensate the deviations and reduce the number of tool revisions, a holistic view of the influencing factors on the geometrical deviation is necessary. In order to address this issue, a hot forging process was developed, whose geometry is prone to high deviations, and a stress-based compensation model was applied. For this, forging experiments were carried out and a comparison was made between the actual geometry and the desired one by means of 3D coordinate measurements. The compensation methodology, which directly takes into account the complex 3D stress states during forming, allows to determine a compensating tool geometry. This opened up the possibility of validating the simulation results and testing a compensation model while eliminating deterministic deviations in hot forging processes.
机译：在热锻造过程中，由于工具和坯料之间的复杂相互作用，所形成的工件的几何形状偏离所需的目标几何形状，这导致不均匀的温度和应力场。通过使用数值模拟，只能通过使用数值模拟来映射得到的偏差，这使得在设计工具时难以考虑。因此，锻造工具的开发需要通过工具几何中的大量修订来迭代适应过程，其升级所产生的成本。为了补偿偏差并减少工具修订的数量，需要对几何偏差的影响因素的整体视图是必要的。为了解决这个问题，开发了一种热锻造过程，其几何形状容易出现高偏差，并应用基于应力的补偿模型。为此，通过3D坐标测量来执行锻造实验，并且在实际几何形状和所需的一个之间进行比较。直接考虑成形过程中的复杂3D应力状态的补偿方法允许确定补偿刀具几何形状。这使得可以验证仿真结果并测试补偿模型的可能性，同时消除热锻造过程中的确定性偏差。

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