DESC:FIELD OF INVENTION:
[001] The present invention relates to a system and method of forging and more particularly relates to system and method of multi axis forging.

BACKGROUND OF INVENTION:
[002] Forging is a manufacturing process involving the shaping of a metal using localized compressive forces through hammering, pressing, or rolling. These compressive forces are delivered with a hammer or a die. Based on the temperature at which the forging is performed, it is categorised as cold, warm or hot forging. A hot forging is defined as a metal shaping process in which a malleable metal part also known as a billet or a work piece is worked to a predefined shape at elevated temperature.

[003] Conventionally a hot forging method involves a metallic work piece or billet to be placed on a bottom die. The metal work is heated generally to 75% of its melting temperature. Then the top die is moved downward to press the hot billet. The top die and bottom die together have the shape of the final product to be made. The cavity formed by the top die and the bottom die is open at parting line. Once the top die is pressed against the bottom die, the heated billet undergoes shape change and the hot billet takes shape of the cavity. The pressing of the hot billet leads to lateral movement of the billet, which is generally termed as flash. Intentionally, the volume of the billet material is more than the required volume of the final product. The excess billet material from the sides of the cavity is trimmed off. The trimmed off material is scrapped and hence decreases the material yield.

[004] Further, it is challenging to use hot forging method for manufacturing parts in which the design is not symmetric such as camshafts, small connectors, etc. For manufacturing such components through current hot forging press, a lot of material squeeze out as flash, which is scrapped, reducing the overall material yield of the process. Additionally, if there is any change in specification of components for e.g. the stem length of a cam shaft is changed and rest of it remains same, then in such case, a whole new die will be manufactured. Conventionally, the existing hot forging machine is using an inefficient method as it incurs substantial material wastage.

[005] According to one of available solutions, a hot forging method, which employ multiple axis die forging. In such arrangement, there are three dimensional forging of the work piece utilizing plurality of dies. For e.g. firstly a work piece (steel bar or billet) is heated, secondly the work piece is placed on a bottom die and thirdly the multiple dies from top and both sides perform the ramming/ pressing. Thereafter, the final product is obtained once the dies are retracted to their initial position.

[006] Similar three dimensional forging system is employed for cold forging where the billet or workpiece is placed in the bottom die at room temperature and further forging is performed by multiple rams. Hence, the final product is obtained after the dies are retracted.

[007] However, the above mentioned solution(s) has/have certain limitations namely, it can be employed for symmetric products only i.e. in case of a non-symmetric product, the available solution may need additional manufacturing process. For e.g. when manufacturing a cam shaft which has different length of stem on sides of the lobes, in one such scenario firstly the final product is made symmetric and then the excess length of stem is machined or in another such scenario non-symmetric product is forged using specific die. The usage of another manufacturing method (such as machining) along with mentioned three-dimensional forging method lead to increase in manufacturing time, cost and lowers the material yield. Also, the usage of multi-axis forging for non-symmetric product in which the horizontal rams are moved towards the billet at same speed, may lead to improper flow of billet material and eventually the material characteristics of the final forged product will have concerns.

[008] Hence, in view of above problems of existing systems there is a clear need to provide an improved multi-axis forging method which can provide high material yield for manufacturing non-symmetric products, efficient cycle time for given product manufacturing, and no additional manufacturing process.

OBJECTIVES OF THE INVENTION:
[009] In light of the aforementioned, it is an objective of this invention to provide a multi-axis forging system and method with high material yield.

[010] Another objective of the present invention is to provide forging system and method for non-symmetrical products.

[011] Another objective of the present invention is to provide a flash less forging system and method.

[012] Yet another objective of the invention is to provide manufacturing system and method which employs less material and reduces machining time.

[013] Still another objective of the invention is to provide a multi-axis forging system and method with controlled fine stroke of punch leading to reduced machining allowances.

[014] Another objective of the present invention is to reduce the manufacturing cost of non-symmetric products.

[015] Other objects and advantages of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying figures, which are not intended to limit the scope of the present disclosure.

SUMMARY OF THE INVENTION:
[016] With these objectives in view, the present invention provides a multi-axis forging system comprising:
a bottom die for placing a billet to be forged;
a plurality of rams configured to move along a plurality of different axes for applying force on the billet for forging;
characterized in that at least one of the plurality of rams includes a provision for controlling the velocities and/ or forces of the ram different from other rams.

[017] According to yet another embodiment, at least one of the plurality of rams comprises at least a cylinder selected from a pneumatic cylinder or a hydraulic cylinder or a servo-hydraulic cylinder to move the ram along a plurality of different axes for applying force on the billet. The cylinder is configured to operate with same or different velocities and/or forces.
[018] According to one of the embodiment, at least one of the plurality of rams includes plurality of horizontal rams.

[019] According to one of the embodiment, at least one of the plurality of horizontal rams are provided at diametrically opposite locations.

[020] According to an embodiment, at least one of the plurality of horizontal rams comprises of a heat shield to prevent damages to the cylinder from high temperature billet and a punch assembly to squeeze the billet. The heat shield is provided between the punch assembly and the cylinder.

[021] According to another embodiment, the velocity and/ or force of at least one of the plurality horizontal rams is controlled by a control system.

[022] According to yet another embodiment, the control system includes a PLC control system configured to control velocities and/ or forces of at least one of the plurality of horizontal rams bases at least one input parameters including required pressure on the billet, required movement distance of the ram, position of the ram, shape of a component to be formed, material of the billet, etc.

[023] According to one of the embodiment, the multi-axis forging system includes the bottom die attached to an upper end of the base plate.

[024] According to one of the embodiment, at least one of the plurality of ram includes a vertical ram that moves along a vertical axis.

[025] According to one of the embodiment, a top die is attached at a lower end to the vertical ram.

[026] According to yet another embodiment, the vertical ram moves downward to clamp the top die with the bottom die, forming a cavity between the dies to accommodate the billet.

[027] According to one of the embodiment, the vertical ram is having a provision to control the velocity and/ or force.

[028] According to yet another embodiment, the system is configured to forge a component of any non-symmetrical, non-uniform, symmetrical or uniform shape having improved material yield.

[029] The forged component is ejected by configuring a multi-point ejection system. The multi-point ejection system includes a central ejector, ejection bridge and ejector pins.

[030] According to another embodiment, the vertical ram comprises a vertical hydraulic piston connected to a flange plate. A heat shield is provided between the flange plate and a top ram plate. The heat shield is configured to provide as an insulation for avoiding heat transfer from the top ram plate to the hydraulic parts.

[031] According to one of the embodiment, the billet provided is a hot billet or has a temperature around 1200 degree Celsius for steel.

[032] According to yet another embodiment, a multi-axis forging method comprising:
placing a billet to be forged onto a bottom die;
applying force on the billet along different axes for forging using plurality of rams;
characterized in that controlling the velocity and/ or force of at least one ram along different axes during forging of the billet.

[033] According to one of the embodiment, the step of applying force to the billet along different axes using plurality of rams includes step of providing a vertical ram with a top die at a lower end of the vertical ram and creating a cavity between the top die and the bottom die for accommodating the billet.

BRIEF DESCRIPTION OF DRAWINGS:
[034] The above and other objects, features, and advantages of the present disclosure will be more apparent from the detailed description taken in conjunction with the accompanying drawings. One or more embodiments of the present invention are now described, by way of example only with reference to the accompanied drawings wherein like reference numerals represent like elements:
[035] Figs. 1a and 1b illustrate a schematic representation of a multi-axis forging system, according to an embodiment of the present disclosure;
[036] Figs. 2a-2e illustrate an isometric view of the multi-axis forging system illustrating various steps followed in the forging method, according to an embodiment of the present disclosure;
[037] Fig. 3 illustrates a schematic representation of lower assembly of the multi-axis forging system, according to an embodiment of the present disclosure;
[038] Fig. 4 illustrates a schematic representation of heat shield of upper assembly of the multi-axis forging system, according to an embodiment of the present disclosure;
[039] Figs. 5a and 5b illustrate an isometric view of final forged product, according to an embodiment of the present disclosure.
DETAIL DESCRIPTION OF DRAWINGS:
[040] A preferred embodiment will now be described in detail with reference to the accompanying drawings. The preferred embodiment does not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.

[041] It will be readily understood that components of present invention as generally described and illustrated in figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the invention as represented in the figures is not intended to limit the scope of the invention but is merely representative of certain examples of presently contemplated embodiments in accordance with the invention. The presently described embodiments will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.

[042] Figs. 1a and 1b illustrate a multi-axis forging system (100) for forging a component according to one of the embodiment of present invention; wherein the multi-axis forging system (100) comprises of a lower assembly (116) and an upper assembly (118). The lower assembly (116) includes a base plate (102), a bottom die (104) and a plurality of horizontal rams (110). The upper assembly (118) includes a vertical ram (106) and a top die (108). The bottom die (104) is attached to an upper end of the base plate (102). Preferably, a hot billet having a temperature around 1200 degree Celsius (for steel) is placed on the bottom die (104); however a cold billet may also be used based on the need of application. A plurality of rams are configured to move along a plurality of different axes to apply force on the billet for forging, wherein at least one of the plurality of rams is provided with cylinders for controlling the velocities and/or force of the rams different from other plurality of ram(s). At least one of the plurality of rams is a vertical ram (106), which is provided with a top die (108) at its lower end. The vertical ram (106) may be operated using cylinder including hydraulic cylinder, servo hydraulic cylinder, pneumatic cylinder or any similar means. The vertical ram (106) moves downward and the top die (108) clamps with the bottom die (104) forming a cavity in which the billet is placed, preferably a hot billet is placed. After the clamping of the bottom die (104) and the top die (108), the vertical ram (106) applies force on the billet. At least one of the plurality of rams includes a plurality of horizontal rams, wherein the plurality of horizontal rams (110) includes at least two horizontal rams (112, 114) (as shown in Fig. 2b) located at diametrically opposite position facing each other. The plurality of horizontal rams (110) are operated using cylinder including hydraulic cylinders, pneumatic cylinders, servo-hydraulic cylinders or any similar means. The plurality of horizontal rams are preferably provided with servo-hydraulic cylinders for movement of the rams with same or different velocities/ forces. The plurality of horizontal rams (110) move forward and apply forming force on the billet from opposite sides. The applied force from all the directions on the billet squeezes the billet’ material and fills the cavity completely i.e. the forces are applied from vertical direction by top vertical ram (106) and in horizontal direction by the plurality of horizontal rams (112, 114).

[043] Further, the lower assembly (116) is provided with ejection system for ejecting forged product from the bottom die (104), the ejection system comprises of a bottom central ejector (120), a bottom ejection bridge (122) and a bottom ejector pin (124). Similarly, the upper assembly (118) is provided with ejection system for ejecting forged product from the top die (108), the ejection system comprises of a top central ejector (130), a top ejection bridge (132) and a top ejector pin (134).

[044] Each of the plurality of horizontal rams (110) comprises of a servo hydraulic cylinder, a heat shield and a punch assembly. The horizontal rams (110) located at diametrically opposite position are operated using servo controlled hydraulic cylinders. The horizontal rams (110) located on the LH side and RH side of the forging system are namely LH horizontal ram (112) and RH horizontal ram (114). The heat shield (136) is provided between the forging tools such as the punch assembly (or dies) and the servo hydraulic cylinder (138), this arrangement helps in preventing damages to the hydraulic parts (vertical hydraulic cylinder and servo-hydraulic cylinders) from high temperature interaction with the high temperature billet. The LH horizontal ram (112) and RH horizontal ram (114) are provided with LH punch assembly (126) and RH punch assembly (128) respectively.

[045] Referring to figs. 2a to 2e, illustrating further details of the multi-axis forging method according to one of the embodiment of present invention. A billet (200) is placed on the bottom die (104) provided on the base plate (102). The top die (108) fixed on the lower end of the vertical ram is moved down onto the bottom die (104). As shown in Fig. 2b, the top die (108) and the bottom die (104) are clamped together forming a cavity (202) between them. As shown in Fig. 2c, the plurality of horizontal rams (110) are brought from opposite ends to squeeze the billets (200) from both ends. The movement of the LH horizontal ram (112) and RH horizontal ram (114) is controlled by PLC controlled servo-hydraulic cylinders. The velocities of each of the horizontal rams (112, 114) may be preferably different and this provides flexibility to control material flow in the cavity (202) and is determined by the type of forged product to be formed. A control system is provided for controlling the plurality of rams (106, 110) including a PLC control system in which input parameters include required pressure on the billet, required movement distance of the ram, position of the ram, shape of the component to be formed, material of the component, etc. The PLC controlled servo-hydraulic cylinders helps in providing predefined inputs to PLC system such that the movement of the cylinders can be controlled i.e. if LH horizontal ram (112) has to be moved X distance and RH horizontal ram (114) has to be moved Y distance, then such movement can be easily achieved with this system. With this arrangement a non-uniform or non-symmetric component can be easily formed in a single stage multi-axis forging system and without forming any flash. Once the forging process is completed, as evident from Figs. 2d and 2e, the horizontal rams (112, 114) are pulled backward and the top die (108) is retracted towards the top. Simultaneously the ejection system ejects the product from the top die and bottom die. The forged component (204) may be unsymmetrical components such as camshaft, small connectors, etc.

[046] Referring to Fig. 3, illustrating multi-point ejection system configured in lower assembly (116) of the multi-axis forging system (100) according to preferred embodiment of the present invention. The multi-point ejection system comprises of a bottom central ejector (320) which pushes a bottom ejection bridge (322) and hence a set of bottom ejector pins (324) ejects the forged product from the bottom die (104). The arrangement of the ejection bridge (332) and the set of ejector pins (324) are such that the ejector pins (324) can be moved laterally as per the required profile of the product. Hence, the individual ejector pins (324) can be moved in synchronous to the design of required forged product, this facilitates in easy removable of different forged product without changing the ejection system or the bottom die in the given multi-axis forging system (100).

[047] Referring to Fig. 4, illustrating heat shield arrangement (400) of the vertical ram according to preferred embodiment of the present invention. The vertical ram (106) comprises of a vertical hydraulic piston (402) connected to a flange plate (404). The heat shield (406) is placed between the flange plate (404) and a top ram plate (408), wherein the heat shield (406) is configured to provide as an insulation for avoiding heat transfer from the top ram plate (408) to the hydraulic parts. The heat shield arrangement (400) ensures the longevity and durability of the hydraulic parts namely vertical hydraulic cylinder and servo-hydraulic cylinders.

[048] Referring to Figs. 5a and 5b, illustrating final forged product (500) according to preferred embodiment of the present invention. The final forged product can be in the form of first type of forged product (502) or second type of forget product (502). The final forget products are non-uniform products which may require numbers of step and low material yield, wherein with the current arrangement these products are formed on a single system, with high material yield and reduced floor space required for the setup.

[049] The present invention is applicable to any type of complex, non-symmetric and non-uniform products which may require no. of steps for manufacturing.

[050] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics or essential characteristics. The described embodiments are to be considered in respects as illustrative and not restrictive.

[051] Although the exemplary forms of the present disclosure have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the present disclosure.

List of Reference Numerals:
100 Multi-Axis Forging System
102 Base Plate
104 Bottom Die
106 Vertical Ram
108 Top Die
110 Horizontal Ram
112 LH Horizontal Ram
114 RH Horizontal Ram
116 Lower Assembly
118 Upper Assembly
120 Bottom Central Ejector
122 Bottom Ejection Bridge
124 Bottom Ejector Pin
126 LH Punch Assembly
128 RH Punch Assembly
130 Top Central Ejector
132 Top Ejection Bridge
134 Top Ejector Pin
136 Heat Shield
138 Servo hydraulic cylinder
200 Billet
202 Cavity
204 Forged Product
300 Lateral Movement
320 Bottom Central Ejector
322 Bottom Ejection Bridge
324 Bottom Ejector Pin
400 Heat Shield of Vertical Ram
402 Vertical Hydraulic Piston
404 Flange Plate
406 Heat Shield
408 Top Ram Plate
500 Final Forged Product
502 First Type of Forged Product
504 Second Type of Forged product
,CLAIMS:We Claim:
1. A multi-axis forging system (100) comprising:
a bottom die (104) for placing a billet (200) to be forged;
a plurality of rams (106, 110) configured to move along a plurality of different axes for applying force on the billet (200) for forging;
characterized in that at least one of the plurality of rams (106, 110) includes a provision for controlling velocities and/or forces of the ram different from other rams.

2. The multi-axis forging system (100) as claimed in claim 1, wherein at least one of the plurality of rams (106,110) comprises at least a cylinder selected from a pneumatic cylinder or a hydraulic cylinder or a servo-hydraulic cylinder to move the ram along a plurality of different axes for applying force on the billet (200).

3. The multi-axis forging system (100) as claimed in claim 2, wherein the cylinder configured to operate with same or different velocities and/or forces.

4. The multi-axis forging system (100) as claimed in claim 2, wherein at least one of the plurality of rams includes plurality of horizontal rams (112,114).

5. The multi-axis forging system (100) as claimed in claim 4, wherein at least one of the plurality of horizontal rams (112, 114) are provided at diametrically opposite locations.

6. The multi-axis forging system (100) as claimed in claim 4, wherein at least one of the plurality of horizontal rams (112, 114) comprises a heat shield (136) to prevent damages to the cylinder (138) from high temperature billet, and a punch assembly (126, 128) to squeeze the billet (200).

7. The multi-axis forging system (100) as claimed in claim 6, wherein the heat shield (136) is provided between the punch assembly (126, 128) and the cylinder (138).

8. The multi-axis forging system (100) as claimed in claim 5, wherein the velocity and/or force of at least one of the plurality of horizontal rams (112, 114) is controlled by a control system.

9. The multi-axis forging system (100) as claimed in claim 8, wherein the control system includes a PLC control system configured to control the velocity and/or force of at least one of the plurality of horizontal rams (112, 114) basis at least one input parameter, including required pressure on the billet, required movement distance of the ram, position of the ram, shape of a component to be formed, and material of the billet.

10. The multi-axis forging system (100) as claimed in claim 1, wherein the bottom die (104) is attached to an upper end of a base plate (102).

11. The multi-axis forging system (100) as claimed in claim 2, wherein at least one of the plurality of ram includes a vertical ram (106) that moves along a vertical axis.

12. The multi-axis forging system (100) as claimed in claim 11, wherein the vertical ram is provided with a top die (108) at a lower end of the vertical ram (106).

13. The multi-axis forging system (100) as claimed in claim 12, wherein the vertical ram (106) moves downward to clamp the top die (108) with the bottom die (104), forming a cavity (202) between the dies (104, 108) to accommodate the billet (200).

14. The multi-axis forging system (100) as claimed in claim 12, wherein the vertical ram (106) comprises a vertical hydraulic piston (402) connected to a flange plate (404).

15. The multi-axis forging system (100) as claimed in claim 14, wherein the vertical ram (106) comprises a heat shield (406) provided between the flange plate (404) and a top ram plate (408).

16. The multi-axis forging system (100) as claimed in claim 11, wherein the vertical ram (106) is having a provision to control the velocity and/ or force.

17. The multi-axis forging system (100) as claimed in claim 1, wherein the system is configured to forge a component (204) of any non-symmetrical, non-uniform, symmetrical or uniform shape.

18. The multi-axis forging system (100) as claimed in claim 17, wherein the forged component (204) is ejected by configuring a multi-point ejection system comprises a central ejector, ejection bridge and ejector pins.

19. A multi-axis forging method (100), comprising:
placing a billet (200) to be forged onto a bottom die (104);
applying force on the billet (200) along different axes using plurality of rams (106, 110) for forging;
characterized in that controlling the velocity and/ or force of at least one ram, along different axes during forging of the billet (200).

20. A multi-axis forging method (100) as claimed in claim 19, wherein the step of applying force to the billet (200) along different axes using plurality of rams (106, 110) includes step of providing a vertical ram with a top die (108) at a lower end of the vertical ram (106) and creating a cavity between the top die (108) and the bottom die (104) for accommodating the billet (200).