Novel multi-level modeling method for complex forging processes on hydraulic press machines

A multi-level modeling method is proposed for complex forging processes on hydraulic press machines (HPMs). This method integrates the microstructure model of a forging into the motion model of the HPM such that the model built can effectively reflect the whole forging process. In order to ease this modeling, the method then divides the complex forging process into many sub-processes, where each sub-process has simpler dynamic behavior than the original process, rendering modeling and experimentation easier. The method also incorporates only some of the unknown parameters. Thus, parameter identification of each sub-process is easier and simpler than in the original process. Moreover, the deformation force model of a forging is derived and its unknown parameters are identified online using the input and output data of the HPM. This renders the deformation process of a forging capable of real-time prediction and control. Both numerical simulation and experiments demonstrate and test the effectiveness of the proposed modeling method.