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Finite Element Method (FEM) simulations are essential for predicting feasibility, outcomes, and defects in hot plastic deformation processes. In small batches or single-component production, a reliable model is crucial to minimise the number of physical trials, material waste, and overall time and energy consumption. However, achieving high simulation accuracy depends on defining precise boundary conditions, particularly regarding material properties and specific process parameters.In hydraulic press forging, a primary challenge involves defining an objective relationship for the downstroke speed, as it strongly influences both the workpiece’s mechanical response and the total operation time.This study presents a methodology to identify the Power Limit (PL) curve of a hydraulic press by correlating the maximum downstroke speed with the applicable forging forces in an industrial context. An extensive dataset, derived from real-world forging operations performed on blanks of different geometries and materials, was processed to construct the curve. The proposed model was validated by comparing FEM results with industrial experimental data, demonstrating high reliability. In addition, the study shows that this approach can be tailored to characterise the most representative forging conditions in terms of forging downstroke speed for specific materials, leading to the definition of a Material Operating Characteristic Curve (MOCC). The model offers a robust framework for enhancing the predictive capability of FEM simulations for hot forging processes.
Keywords: FEM simulations, forging, hydraulic press, power limit curve© This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.