Optimization of processes and systems for a continuous forging process sequence

In drop forging, the main requirements consist in the production of workpieces with pronounced straight or curved main axis while simultaneously maintaining a large variety of forms. The main customer of these drop-forged pieces is the vehicle manufacturing industry with dynamically high-stressed parts used for drives and undercarriages. The optimization of processes and systems for continuous forging process sequences for oblong workpieces with high dimensional and weight accuracies is represented in the form of realized process solutions. Focus is placed on the possible linking of cross-rolling on round- and flat-jaw cross-rolling machines as preforming and finished forming during the production of drop-forged parts and in the optimization of tool technology for the processing steps of drop forging on hammers and presses. Selected application cases are the production of vehicle gear shafts by cross-rolling, the low-flash drop forging of accurately weighted connecting rods and the opt imization of intermediate forms for drop forging light metals by means of cross-rolling. In addition, control optimization of tool-forming machine-systems in the process step of finish forming, the use of prestressed split dies and the use of optimized system solutions for high speed tool changes all represent possibilities for increasing finished form accuracy of forged parts.