Abstract
A free shape forging process is proposed to make products in different shapes and dimensions by one set of dies and its deformation and load characteristics are investigated in case of applying this process to an axisymmetric hot forging of aluminum. The distinctive feature of this process is that the die configuration is composed of punches applying loads to a specimen individually. In this experiment, the lower die had a rectangular shape in the cross section and the upper die set was composed of three punches of the shapes of two concentric rings and one cylinder, each of which could independently apply a quasi-static load to a specimen. Dimensions of specimen and load were measured during forging, and the maximum load was compared with that of a conventional process. This process of one set of dies has been shown to be able to forge various shapes, and the effect of control procedures of the punches on the deformation pattern is discussed. The maximum load of this process is smaller than that of the compared process. This free shape forging process has been demonstrated to be suitable for making products in various shapes in small quantities.
