Browsing by Subject "open-die forging"

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Access status: Open Access ,
Design and implementation of a digital infrastructure for autonomous open-die forging
(Wydawnictwa AGH, 2025) Rechenberg, Roy; Korpala, Grzegorz; Jabłońska, Magdalena; Wojtaszek, Marek; Zyguła, Krystian; Tkocz, Marek; Bednarczyk, Iwona; Kowalczyk, Karolina; Prahl, Ulrich
Open-die forging is a key process for manufacturing large components such as generator shafts and crankshafts for ship engines. Despite its industrial relevance, the process remains dependent on manual labour and operator expertise, leading to challenges in process stability, reproducibility, and efficiency. Traditional automation approaches are impractical due to the high variability and low production volumes typical of open-die forging. At the Institute of Metal Forming (IMF) at the TU Bergakademie Freiberg, a novel concept for autonomous open-die forging has been developed and tested. The system combines conventional forging equipment with advanced technologies, including industrial robotics, 3D laser scanning, thermal imaging, and modular control software. Central to the concept is a robot cell operating as a distributed system, where sensor data is used to create a digital twin of the workpiece. This enables adaptive process planning and real-time autonomous operative adjustments. A process planning tool generates pass sequences and commands for manipulator movements, while an electromechanical interface allows indirect control of the forging press. The modular software architecture, coordinated by a central core-module, ensures flexibility and facilitates integration into different production environments. Initial trials demonstrate the system’s potential to improve process stability and quality while reducing dependency on manual operation. Ongoing work focuses on refining the concept to meet industrial requirements and support advanced material applications.
Access status: Open Access ,
Modelling of microstructure development in forging of a windmill shaft
(2006) Sińczak, Jan; Skubisz, Piotr; Łukaszek-Sołek, Aneta; Pietrzyk, Maciej
The paper presents the results of investigation of microstructure evolution in hot-deformed steel in the process of forging of large forgings. Using a forging of a windmill main shaft as an example, description of the technological process is presented, focused on phenomena occurring in the microstructure during hot-forging. Investigation of the microstructure during and after forging of a shaft was made. The results of theoretical calculation of microstructure evolution during subsequent stages of production cycle are based on temperature changes plots derived from industrial practice. Simulation of microstructure evolution allowed plotting changes of grain size and recrystallized volume fractions versus time during forging and reheating operations.