Computer-aided design of nett-forming by injection forging of engineering components

Methodology and supporting techniques for design are developed with a view to defining a design and analysis system for nett-forming by injection forging. Processes and components were classified with reference to the method of injection, billet geometry, constraint to the billet and auxiliary media. FE simulation approaches were developed to predict flow-dependent flaws; the identified flaws were classified with reference to the mechanism of initiation of the flaws. Using these classifications, forming configurations, parameters and tools are either selected for the specified component by referring to the forming of similar products or designed by using proposed procedures; these procedures enable the design of forming operations to achieve flawless, high-precision products.