Part family methods for bulk metal forming

Abstract

The use of part family or group technology methods for machining operations is well established and several manufacturing systems baaed on this approach are in existence, as well as rationalized and automated procedures for design, process planning, etc. It is less well recognized that a similar approach to metal forming operations can lead to substantial benefits also. In this paper the possibilities for extending this approach to bulk metal forming operations (forging, stamping, etc.)are outlined. In particular systematic procedures for component and die design are described based on classification and coding systems for formed parts. In this context, the selection of forging features (draft, allowances, etc.), billet size estimation, and so on are considered. The use of group die sets, with interchangeable inserts, for families of similar parts is outlined. This technique enables die coats to be substantially reduced thus making forming operations more economically viable for small batches of parts. Combination of these techniques can lead to an integrated system for forming die design and manufacture, starting from the required as machined part through to the finished die.