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By using fast calculation models, the equivalent strain, temperature, and average austenitic grain size in the center of an ingot can be determined. When used in an online process monitor by coupling with a measuring system, these models are fast enough to visualize the current state of an ingot during forging. Based on a model forging process, the use of the program is demonstrated. Comparing results from metallography of the forged billet with the calculated grain size, a good agreement could be achieved (deviation of 6-24%). Even before the forging process, the presented automatic pass schedule optimization can be applied. Through this, a process could be optimized concerning a high homogeneous equivalent strain and a low number of strokes. As result of the optimization, an increasing grain size and temperature could be observed. Thus it could be useful to change other process parameters, like lowering the furnace temperature. [ABSTRACT FROM AUTHOR]

The article presents a study which aims to produce strategies of comprehensive process design and improve machines and tooling technologies for precision forging. It mentions that in the sub-projects B1 Process design for precision forging and B2 Innovative machines and tooling technology for precision forging, the process design and tooling configuration were completed. The study indicates that an elaborated knowledge on the material specific heat balance is required in precise tool design.

The article presents a study on the use of numerical systems in precision forging. It states that the ANSYS® element software with Ansys Parametric Design Language (APDL) and user programmable features (UPF) was used to observe the micro structural developments, such as grain growth and micro structural transformations. Results reveal that a good correlation to the measurements on metallographic specimens was exhibited on the grain sizes of the computed recrystallised microstructure.

The author reflects on the Leibniz University Hanover's collaborative research centre (CRC) 489, which develops and analyzes a process chain from forging technology for production precision forged high performance components. He remarks that CRC 489 considers the process option for precision forging, allowing the recovery of technical and economic advantages. The author suggests consideration of individual processes in dealing with manufacturing precision-forged high performance components.