from the conferences organized by TANGER Ltd.
Finite Element Method (FEM) simulations are essential for predicting feasibility, outcomes, and defects in hot plastic deformation processes. For small batches or single-component production, the use of a reliable model becomes crucial to minimise the number of physical trials, material waste, as well as time and energy consumption. Achieving high simulation accuracy requires setting appropriate boundary conditions, such as material properties and specific process parameters. In hydraulic press forging, one of the main challenges lies in defining an objective relationship for the downstroke speed, which significantly influences the mechanical response of the workpiece and the overall operation time. This study presents a methodology to identify the power limit curve of a hydraulic press, correlating the maximum downstroke speed with the applicable values of the press force in an industrial context. An extensive dataset from real forging operations performed on blanks of different geometries and materials was processed to construct the power limit curve. The proposed model was validated by comparing FEM simulation results with experimental industrial data, demonstrating high reliability. In addition, the study showed that this approach can be tailored to characterise the downstroke speed of the press for specific materials and operations, even if a larger amount of significant data is required. 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.