Quantification of press elasticity in the forging of three-dimensional complex shapes

This paper presents an improved approach to characterize press elastic behaviour and to quantify the effect of press elasticity in the forging of three-dimensional (3D) complex shapes. Using a stiffness matrix formulation, the overall press elasticity is characterized by press elastic deformation and initial clearances of the press guideway. The effect of press elasticity in forging is evaluated by implementing the press stiffness matrix formulation into the 3D forging simulation using a user subroutine. An industrial-based 3D blade forging case study was carried out to assess the robustness and efficiency of this approach in the forging of 3D complex shapes. Compared with cases without press elasticity, the results show that the press elasticity has less effect on forging force requirements, material deformation, and stress and strain distributions. However, the effect of press elasticity is more apparent on the dimensional and shape accuracy of the forged blade with the initial guideway clearance as a major source for dimensional errors compared with the press elastic deformation. The case study also shows that this approach can be easily implemented for evaluating press tool-related effects in forging simulation and design.