Optimisation of processing parameters of the rotary forging of stainless steel and aluminum

Project aim

The aim of this research is to determine the effects that processing parameters have on the rotary forging process. Specifically on the response functions of surface roughness; dimensional variation; residual stress and hardness which will be investigated using a classical design of experiments approach.

Project background

Rotary forging is an incremental cold forming process used to produce near net shape and net shape cylindrical components most commonly in the automotive industry. Advantages of the process include lower levels of vibration and noise; uniform quality; low energy and material costs. While there have been a number of academic studies of rotary forging processes reported, there has been only limited investigation of the empirical relationships between process parameters (e.g. rotational speed, inclination angle) and the properties of the formed part.