Geometric shape errors in forging: Developing a metric and an inverse model

The complexity of the forging process ensures that there is inherent variability in the geometric shape of a forged part. While knowledge of shape error, comparing the desired versus the measured shape, is significant in measuring part quality the question of more interest is what can this error suggest about the forging process set-up? The first contribution of this paper is to develop a shape error metric which identifies geometric shape differences that occur from a desired forged part. This metric is based on the point distribution deformable model developed in pattern recognition research. The second contribution of this paper is to propose an inverse model that identifies changes in process set-up parameter values by analysing the proposed shape error metric. The metric and inverse models are developed using two sets of simulated hot-forged parts created using two different die pairs (simple and 'M'-shaped die pairs). A neural network is used to classify the shape data into three arbitrarily chosen levels for each parameter and it is accurate to at least 77 per cent in the worst case for the simple die pair data and has an average accuracy of approximately 80 per cent when classifying the more complex 'M'-shaped die pair data.