Lehrstuhl für Fertigungstechnologie, Universität Erlangen-Nürnberg

Model-based process layout for cold forging in consideration of tool and press deflection

Datum: 09.08.2012



  • Prof. Dr.-Ing. habil. M. Merklein
  • Prof. Dr.-Ing. habil. K. Willner

Within the investigations, an analytic model was developed for common cold forging processes that represents the workpiece dimensions depending on several influencing parameters in consideration of the interactions between process, tooling system and press. It enables an automated optimization of different setting parameters to ensure high workpiece accuracy. Moreover, the model permits an estimate of achievable tolerance ranges. The analytic model is based on several simulation runs with a combined FE model that includes both the forging process and the deflection characteristics of press and tooling system. The investigations include approaches for an efficient determination of the entire deflection characteristics and its condensed modeling in combination with the FE simulation of a cold forging process to ensure high accuracy and low computing time of the combined FE model. In addition, a considerable reduction of the required amount of simulations was achieved by the utilization of typical process characteristics.