Control of technological parameters in the process of ribbed panel forging: use of measuring equipment and mathematical modeling methods

• Published in: Measurement techniques 2024, Vol.66 (10), p.776-784
• Main Authors: Zharov, M. V., Preobrazhenskii, E. V.
• Format: Article
• Language: English
• Subjects: Analysis; Analytical Chemistry; Characterization and Evaluation of Materials; Control equipment; Critical components; Defects; Deformation; Fabric analysis; Finite element analysis; Finite element method; Forging; Kalman filters; Mathematical models; Measurement Science and Instrumentation; Methods; Monitoring; Numerical analysis; Panels; Physical Chemistry; Physics; Physics and Astronomy; Process parameters; Production processes; Ribbed structures; Sensors; Simulation methods; Temperature distribution
• ISSN: 0543-1972; 1573-8906
• DOI: 10.1007/s11018-024-02291-4

This article discusses the aspects of controlling technological parameters for the isothermal forging of cross-ribbed panels, associated with strict adherence to temperature and rate conditions of deformation. However, to produce defect-free panels, because of errors and external disturbances, the control of technological parameters based only on the measurement results of temperature field sensors is often insufficient. The metal temperature at the deformation site can only be estimated indirectly. By analogy with the Kalman filter, a method is proposed for monitoring the technological parameters of the process of isothermal forging of ribbed panels based on a set of results obtained from sensors and calculated by the finite element method. The accuracy and speed of calculating a finite element forging model in four widely used specialized software products, DeForm, QForm, Forge NxT, and Simufact Forming, were studied. Comparing the data obtained during the analysis confirmed the high degree of reliability of the modeling results and demonstrated the potential possibility of controlling the technological parameters for the production of defect-free products using the proposed method. The finite element method in a two-dimensional formulation of the problem provided an acceptable velocity for numerical simulation while monitoring the progress of operations in real time. The results obtained are relevant for metallurgical enterprises producing critical parts for the aircraft and space industries. Therefore, there are increased requirements for production processes to comply with the range of permissible changes in technological parameters.