Method and apparatus for optimizing forging processes

1. A method of forging of a workpiece that is moved along a longitudinal axis of a forging press and having first and second ends transverse thereto, comprising:

detecting the relative positions of the first and second ends of the workpiece along the longitudinal axis by detecting the presence of each of the first and second ends as each of the first and second ends crosses a measuring plane transverse to the longitudinal axis, calculating a length of the workpiece between the first and second ends,

determining the intial height (H o ) of the workpiece transverse to the longitudinal axis, and

calculating a bite ratio (S b /H o ) for a prospective forging location on the workpiece, wherein S b is an effective flat die width of the forging press, and

determining if the bite ratio is greater than 0.5.

2. The method according to claim 1 , wherein detecting the relative positions of the first end and second end is performed using a laser scanning apparatus.

3. The method according to claim 1 , wherein if the calculated bite ratio is greater than 0.5, identifying the prospective forging location as a proposed forging location.

4. The method according to claim 3 , wherein after a forging blow is performed by the forging press:

the relative positions of the first and second ends of the workpiece along the longitudinal axis is detected and calculating a length of the workpiece therebetween; and

iteratively moving the workpiece along the longitudinal axis to a new proposed forging location and determining if the bite ratio is greater than 0.5.

5. The method according to claim 4 , further comprising calculating center line consolidation for the proposed forging location prior to performing the forging blow.

6. The method according to claim 5 , wherein the center line consolidation is calculated by the equation:

d n =S b −H o /F , where if ( d n <0)then d n =0 and F≧ 2

where:

d n is the width of the center line consolidation area of the stroke and

n is the stroke number

S b is the effective flat die width

H o is the workpiece height and

F is an empirical factor with a minimum value of 2.

7. The method according to claim 6 , wherein the centerline consolidation is calculated by the equation:

D=combined sum of d n

where:

D is the combined total width of the consolidation areas along the central axis where overlapping areas are not included in the calculation.

8. The method according to claim 7 , wherein the center line consolidation is calculated by the equation:

Q= 100%· D/L

where:

Q is the percentage quality of center line consolidation and

L is the length of the workpiece.

9. The method according to claim 7 , wherein the center line consolidation is output graphically.

10. The method according to claim 3 , wherein after a forging blow is performed at a location the locations of the forging blows are output graphically.

11. The method according to claim 3 , wherein the prospective forging location is automatically selected as the actual forging location.

12. The method according to claim 1 , wherein if the calculated bite ratio is less than or equal to 0.5 the step of iteratively moving the workpiece along the longitudinal axis to a new proposed forging location until the calculated bite ratio is greater than 0.5 and identifying the prospective forging location as a proposed forging location.

13. The method according to claim 12 , wherein after a forging blow is performed by the forging press:

detecting the relative positions of the first and second ends of the workpiece along the longitudinal axis and calculating a length of the workpiece therebetween; and

iteratively moving the workpiece along the longitudinal axis to a new proposed forging location and determining if the bite ratio is greater than 0.5.

14. The method according to claim 13 , further comprising calculating a center line consolidation for the proposed forging location prior to performing the forging blow.

15. A system for the forging of a workpiece that is moved along a longitudinal axis of a forging press and having first and second ends transverse thereto according to the method of claim 1 , comprising:

a means for detecting the relative positions of the first and second ends of the workpiece along the longitudinal axis by detecting the presence of each of the first and second ends as each of the first and second ends crosses a measuring plane transverse to the longitudinal axis,

a means for calculating a length of the workpiece between the first and second ends,

a means for determining the intial height (H o ) of the workpiece transverse to the longitudinal axis, and

a means for calculating a bite ratio (S b /H o ) for a prospective forging location on the workpiece, wherein S b is an effective flat die width of the forging press, and

a means for determining if the bite ratio is greater than 0.5.

16. The system according to claim 15 , wherein the means for detecting the relative positions of the first end and second end is a laser scanning apparatus.