Optimisation of pass schedules for flat-tool forging based on analytical method

For the incremental bulk forming, semi-empirical analytical methods take great advantage in forming process planning due to their efficiency in calculating deformation and temperature for the whole process. In this paper, based on explicit differential method, a model to predict the evolution of temperature during forging process is proposed. By incorporating this model with the semi-analytical model for deformation presented earlier by the authors, an efficient simulation method for analysing open-die forming process is established. A case study is carried out and the results of deformation and temperature fields predicted by using presented analytical method are quite close to those predicted by finite element method. A set of process schedules are designed and an optimisation is carried out according to the proposed evaluation indexes. The results show that comparatively larger feed ratio and smaller reduction ratio are more favourable to obtain better deformation homogeneity and compact effect.