Virtual set up of multi-stage presses for forging technology integrated with process design

In the current practice the set-up of multi-stage transfer presses results to be an intensive-labour and time-consuming activity which considerably contributes to the increase of non operational time of the press. Considering the high production rates of these machines when equipped with automatic transfer devices, as well as the high investments for equipment and tooling, a reduction of non operational time of the press can lead to an appreciable increase of production efficiency. A Virtual Environment has been developed and implemented for the design and test of the forging process. It consists of a set of software modules specifically devoted to assist the process designer in a set of tasks including (i) design of the forging sequence, (ii) design of components and assembly of the tooling system, and (iii) timing and setting up of the press. By this approach, the setting up of a press is moved from the operative level of the shop floor to the more decisional level of process planning, where preforms and tooling are designed. The present paper is focused on the module for timing and setting up of the press. This module assists the process designer in the off-line determination of press parameters for a specific forging task. It is based on 3D parametric models of the objects and their animation in the working area of the press according to the kinematics of the machine. It allows a correct timing of movements of punches, ejectors, grippers and blanks without collisions and blank dropping. The virtual set-up has been applied in industrial environment and has demonstrated advantages summarised as follows: (i) easy generation and test of alternative sets of adjustment parameters, (ii) reduction of modifications of the tooling system, and (iii) considerable reduction of the time for setting up and timing of the press and, therefore, of the total lead time to manufacture.