Development of a CAD/CAM system for the closed-die forging process

The application of computer-aided engineering (CAE), computer-aided design (CAD), and computer-aided manufacturing (CAM), is essential in modern metal forming technology. Thus, the process of modelling for the investigation and understanding of deformation mechanics has become a major concern in recent and advanced research, and the finite element method (FEM) has assumed increased importance, particularly in the modelling of deformation processes. This work is devoted to the development of a CAD/CAM system for the closed-die forging process. The system development consists of three stages: namely, metal flow simulation, die failure analysis and design optimisation, and the development and implementation of a machining code. In the first stage, the FEM was used to simulate the axisymmetric closed-die forging process of copper material. The method is used to study the metal flow; die filling, retaining the non-linearity involved in the large change in the geometry; the continuous change in the contact surface condition; and the isotropic material work-hardening characteristics. In the second stage, a finite element analysis and optimisation algorithm is developed to examine the die fatigue life and to optimise the die design. The finite element analysis in the first and second stage was carried out using commercially available finite element software called LUSAS. In the third stage, a machining code for the optimised die is developed and implemented using CAD/CAM software called UniGraphics and CNC machine.