Knowledge-Based Die Design Method for Cold and Warm Forging Dies Shared in a Series of Forming Stages in Sequential Forging Press

This paper proposes a general forging die design with sequential forging press extension (GeneDieSFX) method, which is based on an extension of the general forging die design (GeneDie) method, for totally non-axisymmetric cold- and warm-forged products that can be deformed using the sequential forging press (SFP) method. The SFP method uses two punches located on the left and right sides of the upper and lower dies and shares the same dies while exchanging these punches in all forming stages. The basic die structure, which represents the relative positional interrelationships among the various components of the forging dies, is extended to support a new die structure for the SFP method. The forming surface configuration, which represents the correspondence between the functions allocated to the surfaces of the forging dies and the surfaces of the forged product, is also extended to distinguish the forming surfaces of the two punches that press the work material from the left and right sides. In addition, a die unification procedure is introduced to share the dies in all forming stages. An experimental knowledge base for die design support was developed and applied to process plans designed by an experienced engineer for forming of an electrical connector. The experimental results show that the proposed method can generate forging dies that are functionally comparable with dies designed by the experienced engineer.