Development of a new and high-performance precision forging technology

Abstract The article presents the results of research focused on the development of an innovative precision forging technology for austenitic stainless steel forgings, aimed at significantly improving process efficiency. Due to strong material-to-tool adhesion and reduced tool life, austenitic steel presents greater technological challenges compared to carbon steels. The objective of the study was to transition from a four-impression to an eight-impression forging system by redesigning the tooling and optimizing the process through numerical modelling (Forge® NxT) and technological trials. The analyses confirmed that the LASCO HO-U 200 hammer possesses a substantial energy reserve, enabling the efficient forging of eight components simultaneously. A new billet and die cavity geometry was developed, and the proposed technology was experimentally validated. The conducted measurements confirmed compliance with the required quality parameters, including microstructure, hardness, and dimensional accuracy. The implementation of the eight-impression configuration resulted in an over 80% increase in productivity and a reduction in energy consumption per forging by more than 30%. Additionally, the number of cycles required to produce the same number of components was reduced, contributing to lower operating costs, improved process reliability, and enhanced overall production efficiency. The results of the research and experimental work confirm the effectiveness of numerical modelling as a powerful tool in the development of advanced forging technologies while maintaining high product quality.