Analysis of common mould material organisation and mould life prediction algorithm based on machine vision

The study addresses poor plasticity and toughness in steel plate forming by proposing a microstructure analysis and mould life prediction algorithm using machine vision. A distance sensor determines the forging edge, while a displacement sensor and industrial camera enhance measurement accuracy. The system utilises OpenCV to improve image processing speed and precision. A wear simulation for U-shaped hot forming moulds is developed using numerical methods to predict the effect of process parameters on wear depth and distribution. Results show that wear is most significant in the arc area, especially at the upper fillet, and the wear location shifts with increased forming cycles. The optimal superclosure value of 0.6 δ yields a 1.16% error between simulation and experimental results. The study concludes with an optimised wear model for predicting mould life, based on pin disk wear tests and finite element analysis.