Characterisation and development of rotary forging process

Project aim

The project has enabled a better understanding of the rotary forging process through the development of a robust finite element process model and through a series of experiments which helped gained an in-depth understanding of the process behaviour and deformation mechanism during the rotary forging process.

Project background

Rotary forging is an incremental metal forming process that offers excellent benefits over conventional forging processes. Some of its benefits are a massive reduction in forming load, relatively low energy cost, high material utilisation, better material formability, and high flexibility. This has attracted significant interest from the aerospace industry. Rotary forging seems to fit perfectly well as an alternative low-cost manufacturing process.

It is an ideal process for low volume and high-value production. In comparison to conventional forming processes, very little knowledge has been accumulated over the past 100 years since its invention. process design rules and guidelines are almost non-existent. This narrows the process design method to mostly trial and error method. This project aims to develop a better understanding of the process through the use of modern metal forming analysis techniques and through series of experiments.