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Approximate-model based estimation method for dynamic response of forging processes

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Abstract

Many high-quality forging productions require the large-sized hydraulic press machine (HPM) to have a desirable dynamic response. Since the forging process is complex under the low velocity, its response is difficult to estimate. And this often causes the desirable low-velocity forging condition difficult to obtain. So far little work has been found to estimate the dynamic response of the forging process under low velocity. In this paper, an approximate-model based estimation method is proposed to estimate the dynamic response of the forging process under low velocity. First, an approximate model is developed to represent the forging process of this complex HPM around the low-velocity working point. Under guaranteeing the modeling performance, the model may greatly ease the complexity of the subsequent estimation of the dynamic response because it has a good linear structure. On this basis, the dynamic response is estimated and the conditions for stability, vibration, and creep are derived according to the solution of the velocity. All these analytical results are further verified by both simulations and experiment. In the simulation verification for modeling, the original movement model and the derived approximate model always have the same dynamic responses with very small approximate error. The simulations and experiment finally demonstrate and test the effectiveness of the derived conditions for stability, vibration, and creep, and these conditions will benefit both the prediction of the dynamic response of the forging process and the design of the controller for the high-quality forging. The proposed method is an effective solution to achieve the desirable low-velocity forging condition.

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Authors and Affiliations

  1. State Key Laboratory of High Performance Complex Manufacturing, Central South University, Changsha, 410083, China

    Jie Lei, Xinjiang Lu, Yibo Li, Minghui Huang & Wei Zou

Authors
  1. Jie Lei
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  2. Xinjiang Lu
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  3. Yibo Li
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  4. Minghui Huang
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  5. Wei Zou
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Corresponding author

Correspondence to Xinjiang Lu.

Additional information

Supported by National Basic Research Program of China(973 Program, Grant No. 2011CB706802), National Natural Science Foundation of China (Grant No. 51205420), Program for New Century Excellent Talents in University of China(Grant No. NCET-13-0593), and Hunan Provincial Natural Science Foundation of China(Grant No. 14JJ3011)

LEI Jei, born in 1988, is currently a graduate student at School of Mechanical & Electrical Engineering, Central South University, China. His interests include large die forging equipment.

LU Xinjiang is currently an associate professor at School of Mechanical & Electrical Engineering, Central South University, China. His research interests include system design, process modeling and control, robust design, and integration of design and control.

LI Yibo, born in 1981, is currently a lecturer at School of Mechanical & Electrical Engineering, Central South University, China.

HUANG Minghui is currently a professor at School of Mechanical & Electrical Engineering, Central South University, China. His research interests include machine design and manufacturing, design theory, fault diagnosis, and digital manufacturing.

ZOU Wei, born in 1992, is currently a graduate student at School of Mechanical & Electrical Engineering, Central South University, China.

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Lei, J., Lu, X., Li, Y. et al. Approximate-model based estimation method for dynamic response of forging processes. Chin. J. Mech. Eng. 28, 565–572 (2015). https://doi.org/10.3901/CJME.2015.0114.015

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  • DOI: https://doi.org/10.3901/CJME.2015.0114.015

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