SMX FORGING STRATEGY

Abstract

A method for radial forging a workpiece from an initial state to an end state, preferably follows a pass schedule multiple times from an initial state to an end state, by means of a radial forging machine with forging tools, preferably four forging tools, arranged around the periphery of the workpiece. The radial forging machine is designed and configured to perform the radial forging in at least three modes of operation, A) radial forging in spiral mode, B) radial forging in straight mode and C) radial forging in flat mode. The shaping of the workpiece from an initial state to an end state is a sequence of radial forging passes. At least two of the three different modes of operation are applied in succession.

Claims

1-14. (canceled)

15. A method for radial forging comprises: providing a radial forging machine having forging tools arranged around a periphery of a workpiece, the radial forging machine being designed and configured to perform the radial forging in at least three modes of operation, including radial forging in a spiral mode, radial forging in a straight mode, and radial forging in flat mode; and shaping of the workpiece from an initial state to an end state in a sequence of radial forging passes, wherein the sequence of radial forging passes includes operating the radial forging machine in at least two of the at least three modes of operation.

16. The method for radial forging according to claim 15, wherein the forging tools are four forging tools arranged around the periphery of the workpiece, and wherein the sequence of radial forging passes are part of a pass schedule.

17. The method according to claim 15, wherein the shaping of the workpiece comprises radial forging in spiral mode, followed by radial forging in straight mode, followed by radial forging in spiral mode.

18. The method according to claim 15, wherein the shaping of the workpiece comprises radial forging in straight mode, followed by radial forging in spiral mode, followed by radial forging in straight mode.

19. The method according to claim 15, wherein the shaping of the workpiece comprises radial forging in straight mode, followed by radial forging in spiral mode, followed by radial forging in straight mode, followed by radial forging in flat mode.

20. The method according to claim 15, wherein all of the at least three modes of operation are used when shaping the workpiece from the initial state to the end state.

21. The method according to claim 16, wherein the pass schedule is effected as a function of a material of the workpiece.

22. The method according to claim 15, further comprising optimizing a surface of the workpiece in a final finishing pass.

23. The method according to claim 15, wherein operating in spiral mode includes rotating the workpiece about a longitudinal axis at a predetermined angle of rotation after each forging tool stroke, and wherein all of the forging tools participate in the shaping.

24. The method according to claim 15, wherein operating in straight mode does not includes any rotation of the workpiece after each tool stroke, and wherein all of the forging tools participate in the shaping.

25. The method according to claim 16, wherein only opposite forging tools of the four forging tools arranged around the periphery of the workpiece participate in the shaping while operating in flat mode.

26. The method according to claim 25, wherein those of the four forging tools that do not participate in the shaping are positioned on the periphery of the workpiece in order to limit a lateral widening of the workpiece.

27. A radial forging machine, comprising a control device, which is designed and configured to calculate an optimum pass sequence for the workpiece and to preset the radial forging machine for carrying out the method according to claim 15.

28. The radial forging machine according to claim 27, wherein the control device is designed and configured to control the radial forging machine based on a pass schedule calculation program, which takes into account a start geometry and a desired end geometry along with a start temperature of the method for radial forging and a material quality of the workpiece.

29. The radial forging machine according to claim 28, wherein, in addition to the start geometry and the desired end geometry, the pass schedule calculation program also takes into account intermediate dimensions of the workpiece to achieve an optimum distribution of changes to shape in the workpiece.

30. The radial forging machine according to claim 27, wherein control of the radial forging machine is effected taking into account a maximum machine force along with geometries of available forging tools.

31. The radial forging machine according to claim 27, wherein in flat mode, in which only two opposite forging tools of four forging tools arranged around the periphery of the workpiece, can be controlled in such a manner that they participate in the shaping, and wherein forging tools that do not participate in the shaping are adjustable to the periphery of the workpiece such that a lateral widening of the workpiece is at least limited.

Description

DETAILED DESCRIPTION

[0013] A method for radial forging a workpiece from an initial state to an end state is provided, wherein the radial forging is preferably effected following a pass schedule multiple times from an initial state to an end state by means of a radial forging machine, which comprises forging tools arranged around the periphery of the workpiece. Preferably, four forging tools are arranged around the periphery of the workpiece. The radial forging machine is designed and configured so that it can carry out radial forging in at least three modes of operation, namely A) in spiral mode, B) in straight mode and C) in flat mode. The shaping of the workpiece is effected from an initial state to an end state in a sequence of radial forging passes, wherein at least two of the three different modes of operation are applied consecutively, i.e. directly and without an intermediate pass.

[0014] The disclosure refers to a pass as a sequence of shaping processes in a predetermined mode of operation over the entire length of the workpiece or at least a predetermined partial length of the workpiece. The method for radial forging comprises at least two different and successive modes of operation, for example a first pass in spiral mode, followed by a second pass in straight mode, followed again by a third pass in spiral mode, possibly followed by a flat mode. Any conceivable combination of modes of operation in the pass sequence is covered by the concept in accordance with the disclosure as long as two successive passes implement different modes of operation. This means that the method also covers pass sequences with which a plurality of successive passes implement the same mode of operation, but are then followed by a different mode of operation. If necessary and preferred, a surface optimization is achieved at the end of the shaping process within the method by means of a finishing pass. The finishing pass is not taken into account as a shaping operation and therefore does not represent a separate mode of operation.

[0015] With the method in accordance with the disclosure, an improvement in the local change in shape and thus an improvement in product quality can be achieved. Additionally, a shortening of the process chain can be achieved by reducing pre-forging processes. The method enables a shaping method optimally adapted to the workpiece and its material quality, in particular with the best possible through-forging of the workpiece as a whole and taking into account the distribution of changes to shape within the workpiece.

[0016] It is preferable if the application and/or the order of the different modes of operation is effected as a function of the material of the workpiece. Advantageously, the specific requirements that need to be particularly considered for certain materials can be utilized when creating the pass schedule. In particular, it is preferable if different materials can be grouped into material classes, which can be subjected to the same sequence of modes of operation if necessary. These material classes are, for example: Carbon steels, heat-treatable steels, high-speed steels, cold-work steels, hot-work steels, rust and acid-resistant steels, nickel-based alloys, high-temperature steels and titanium alloys, to name but a few. Each material class can have special requirements with regard to the radial forging method, which can then have an influence on the selection of the modes of operation and the order of the modes of operation to be used, depending on the material.

[0017] In this connection, it is preferable if a rotation of the workpiece is effected about its longitudinal axis at a previously set angle of rotation after each forging tool stroke in the mode of operation of spiral mode. In doing so, it is preferable if all forging tools participate equally in the shaping.

[0018] In an equally preferred embodiment, no rotation whatsoever of the workpiece about its longitudinal axis is effected after each tool stroke in the mode of operation of straight mode. In this connection, it is particularly preferable if all forging tools participate equally in the shaping.

[0019] In a further preferred embodiment, in the mode of operation of flat mode, shaping is effected only by oppositely arranged forging tools, preferably by two oppositely arranged forging tools out of a total number of four forging tools arranged around the periphery of the workpiece. In flat mode, the tools that do not participate in a first shaping operation or only participate to a limited extent can be controlled differently with regard to time or shaping dimension than the forging tools described above that participate in the shaping. Likewise, the forging tools that do not participate in the shaping can only be positioned close to the workpiece in order to at least limit and preferably completely prevent a lateral widening of the workpiece during the radial forging process. Finally, the forging tools that do not participate in the shaping can of course also remain in an initial position and not make contact with the workpiece, at least for a limited time.

[0020] Preferably, the method is carried out with a control device, which is designed and configured to calculate an optimum pass sequence for the workpiece and then preset the radial forging machine such that the optimum pass sequence is carried out. In this connection, it is particularly preferable if the control of the radial forging machine is performed on the basis of a pass schedule calculation program, which generates an optimum pass sequence taking into account the optimum forging strategies. Preferably, in addition to the start and end geometry of the workpiece, the start temperature, for example the furnace temperature, and particularly preferably the material quality is also preset. The technology program can then calculate the best pass sequence using all possible forging strategies. It is particularly preferable if the intermediate dimensions after each tool stroke and the forging strategy are calculated in such a manner that the best distribution of changes to shape is achieved at the end of the pass sequence. This can be effected, for example, by comparing the distribution of changes to shape at the end of the process by calculating all possible combinations of pass sequences along with passes of different modes of operation. In particular, the design of the forging strategy is preferably effected taking into account the system force along with the available tool geometries.

[0021] A technology program for calculating pass schedules particularly suitable for such purposes is the Comforge technology package, which, with its data on all industrially relevant materials, possesses all the prerequisites to calculate the corresponding pass schedules. Comforge provides system operators with a comprehensive database for trouble-free and technologically proven forging processes. It is particularly preferable if an automation system monitors and controls all system components, control devices and sensors. As a result, through the appropriate application of the Comforge technology package, the entire forging process from start to finish can be pre-calculated and modeled, including the geometry of the shaping, the forces thereby involved, the temperatures to be observed along with the time required for each pass throughout the entire forging process.

[0022] In accordance with a second aspect, a radial forging machine is provided for carrying out the method in accordance with the first aspect of the disclosure. The radial forging machine is provided with a control device, which is designed and configured to perform the control of the radial forging machine on the basis of a pass schedule calculation program. This pass schedule calculation program gives priority to the start and desired end geometry along with the start temperature of the radial forging process along with the material quality of the workpiece itself.

[0023] In this connection, it is particularly preferable if the pass schedule calculation program also takes into account intermediate dimensions of the workpiece with the aim of achieving an optimum distribution of changes to shape on the workpiece.

[0024] The system operator is provided with a method and a radial forging machine intended for this purpose, which are capable of enabling optimum shaping of the workpiece adapted to the material quality and using a sequence of comparatively easily controllable processes.