Details
| Original language | English |
|---|---|
| Title of host publication | 28th International ESAFORM Conference on Material Forming, ESAFORM 2025 |
| Editors | Pierpaolo Carlone, Luigino Filice, Domenico Umbrello |
| Pages | 917-926 |
| Number of pages | 10 |
| Publication status | Published - 7 May 2025 |
| Event | 28th International ESAFORM Conference on Material Forming, ESAFORM 2025 - Paestum, Italy Duration: 7 May 2025 → 9 May 2025 |
Publication series
| Name | Materials Research Proceedings |
|---|---|
| Volume | 54 |
| ISSN (Print) | 2474-3941 |
| ISSN (electronic) | 2474-395X |
Abstract
Flash formation is a characteristic feature of impression die forging, resulting from the expulsion of excess material through the gap between the upper and lower dies. This expulsion is a consequence of the backpressure generated by the material flow, which ensures complete filling of the die cavity. However, this increases material consumption and requires additional post-processing to remove the flash. Flash formation is influenced by process parameters such as die closure, workpiece temperature, forming speed, forming force and lubrication. Improper control of these parameters can lead to excessive or uneven flash formation and incomplete die filling. Finite element method (FEM) simulations show that different flash geometries require varying press forces to fully form the forged parts. The ratio between flash width and thickness affects the contact stresses in the flash land zone, which in turn influence tool wear and energy costs in the forging process. In this work, a method for automated in-line monitoring of flash formation in a serial forging process using laser triangulation is presented. The study aims to explore a potential correlation between the flash contour length and flash thickness, grounded in the principle of volume constancy, using a demonstrator forging component as a case study. To quantify this interaction, a metric is developed to assess die filling and process quality for application in real-time monitoring. Changes in this metric during serial forging processes provide insights into process parameters and identify possible interactions with these factors. Beyond real-time monitoring, the acquired sensor data can serve as a basis for data-driven process modelling. The findings of this study contribute to the development of an improved process model by integrating sensor-based laser triangulation data into adaptive control strategies. Future work will focus on leveraging artificial intelligence (AI) to analyse complex parameter interactions, detect process fluctuations, and optimize forging operations. This approach paves the way for intelligent, self-adaptive process control, reducing material waste and improving efficiency in serial forging applications.
Keywords
- Flash Formation, Forging Quality, Laser Triangulation, Process Monitoring
ASJC Scopus subject areas
- Materials Science(all)
- General Materials Science
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28th International ESAFORM Conference on Material Forming, ESAFORM 2025. ed. / Pierpaolo Carlone; Luigino Filice; Domenico Umbrello. 2025. p. 917-926 (Materials Research Proceedings; Vol. 54).
Research output: Chapter in book/report/conference proceeding › Conference contribution › Research › peer review
}
TY - GEN
T1 - Laser triangulation for quality monitoring in automated series forging processes
T2 - 28th International ESAFORM Conference on Material Forming, ESAFORM 2025
AU - Glaubitz, Claudia
AU - Rothgänger, Marcel
AU - Ortlieb, Eduard
AU - Peddinghaus, Julius
AU - Brunotte, Kai
N1 - Publisher Copyright: © 2025, Association of American Publishers. All rights reserved.
PY - 2025/5/7
Y1 - 2025/5/7
N2 - Flash formation is a characteristic feature of impression die forging, resulting from the expulsion of excess material through the gap between the upper and lower dies. This expulsion is a consequence of the backpressure generated by the material flow, which ensures complete filling of the die cavity. However, this increases material consumption and requires additional post-processing to remove the flash. Flash formation is influenced by process parameters such as die closure, workpiece temperature, forming speed, forming force and lubrication. Improper control of these parameters can lead to excessive or uneven flash formation and incomplete die filling. Finite element method (FEM) simulations show that different flash geometries require varying press forces to fully form the forged parts. The ratio between flash width and thickness affects the contact stresses in the flash land zone, which in turn influence tool wear and energy costs in the forging process. In this work, a method for automated in-line monitoring of flash formation in a serial forging process using laser triangulation is presented. The study aims to explore a potential correlation between the flash contour length and flash thickness, grounded in the principle of volume constancy, using a demonstrator forging component as a case study. To quantify this interaction, a metric is developed to assess die filling and process quality for application in real-time monitoring. Changes in this metric during serial forging processes provide insights into process parameters and identify possible interactions with these factors. Beyond real-time monitoring, the acquired sensor data can serve as a basis for data-driven process modelling. The findings of this study contribute to the development of an improved process model by integrating sensor-based laser triangulation data into adaptive control strategies. Future work will focus on leveraging artificial intelligence (AI) to analyse complex parameter interactions, detect process fluctuations, and optimize forging operations. This approach paves the way for intelligent, self-adaptive process control, reducing material waste and improving efficiency in serial forging applications.
AB - Flash formation is a characteristic feature of impression die forging, resulting from the expulsion of excess material through the gap between the upper and lower dies. This expulsion is a consequence of the backpressure generated by the material flow, which ensures complete filling of the die cavity. However, this increases material consumption and requires additional post-processing to remove the flash. Flash formation is influenced by process parameters such as die closure, workpiece temperature, forming speed, forming force and lubrication. Improper control of these parameters can lead to excessive or uneven flash formation and incomplete die filling. Finite element method (FEM) simulations show that different flash geometries require varying press forces to fully form the forged parts. The ratio between flash width and thickness affects the contact stresses in the flash land zone, which in turn influence tool wear and energy costs in the forging process. In this work, a method for automated in-line monitoring of flash formation in a serial forging process using laser triangulation is presented. The study aims to explore a potential correlation between the flash contour length and flash thickness, grounded in the principle of volume constancy, using a demonstrator forging component as a case study. To quantify this interaction, a metric is developed to assess die filling and process quality for application in real-time monitoring. Changes in this metric during serial forging processes provide insights into process parameters and identify possible interactions with these factors. Beyond real-time monitoring, the acquired sensor data can serve as a basis for data-driven process modelling. The findings of this study contribute to the development of an improved process model by integrating sensor-based laser triangulation data into adaptive control strategies. Future work will focus on leveraging artificial intelligence (AI) to analyse complex parameter interactions, detect process fluctuations, and optimize forging operations. This approach paves the way for intelligent, self-adaptive process control, reducing material waste and improving efficiency in serial forging applications.
KW - Flash Formation
KW - Forging Quality
KW - Laser Triangulation
KW - Process Monitoring
UR - http://www.scopus.com/inward/record.url?scp=105008078977&partnerID=8YFLogxK
U2 - 10.21741/9781644903599-98
DO - 10.21741/9781644903599-98
M3 - Conference contribution
AN - SCOPUS:105008078977
SN - 9781644903599
T3 - Materials Research Proceedings
SP - 917
EP - 926
BT - 28th International ESAFORM Conference on Material Forming, ESAFORM 2025
A2 - Carlone, Pierpaolo
A2 - Filice, Luigino
A2 - Umbrello, Domenico
Y2 - 7 May 2025 through 9 May 2025
ER -