Research on some basic deformations in free forging with robot and servo-press

Due to the disadvantages in casting or hot forging of Ti alloy artificial bones, such as low strength and high energy cost, this paper prompted an alternative method to manufacture individuated artificial bones. Free forging with a 6-axis freedom robot and servo-press could be very economical in the forming of complex shape parts because of its high flexibility and simple die-setting. Based on this system, the authors studied deformations of some basic elements, which could be assembled to artificial bones with complex shape. Firstly, the compression limit and effect of compression parameters on the roundness during reducing diameter process were declared for Al alloy and pure Ti. Secondly, an approximate theoretical equation of bending angle or curvature radius was proposed, and it matches experimental results well. Finally, a dimension prediction equation was presented by considering effect of material anisotropy, and then the ladder part without width spread was manufactured accordingly.