JP2008284604A - Designing system for process of cogging and cogging method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a designing system and an apparatus for a process of cogging, wherein working conditions such as press-down rate and targeted shape, can be decided with a simple calculation, in spite of the experience difference between press-operators, in the cogging process for forming into a shaft material such as round bar, from a blank with a free-forging. <P>SOLUTION: The designing system for the process of cogging, in which the blank is finished to the shaft material by alternately repeating a press-down movement from the both sides of the blank and a feeding movement to the axial direction, has; a step 1, in which the last octagonal shape and the last square shape at this front step, are decided from the cross-sectional shape of the product shaft material; a step 2, in which when the pass number of times from the blank to the last square shaped size and two process, are defined as one pass unit U, a target shape size is decided at each one pass unit and the press-down rate in each pass is set by predicting the shape of the material to be cogged in each pass unit; a step 3, in which the size of the material to be cogged is measured in each pass unit; and a step 4, in which the press-down rates on and after following pass are corrected by comparing the above measured size and the target size. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a forging process design system for forming a steel bar from a steel ingot into a round bar or the like, a forging method and a forging apparatus using the same.

  Using a free forging press, the material to be machined such as a steel ingot is repeatedly pressed down from two opposite directions perpendicular to the axial direction and the feeding operation in the axial direction alternately. After forging into a final octagonal shape after forming, the forging process for forming into a shaft such as a round bar has conventionally determined the processing conditions such as the amount of reduction, feed, and target shape based on the experience of the press operator. It was. An experienced press operator predicts the deformation behavior of a work material based on experience and intuition and creates a target shape, while an inexperienced press operator performs as much as an experienced press operator. The deformation behavior of the (wrought material) cannot be predicted. For this reason, the experienced press operator and the inexperienced press operator have a problem that there is a large variation in forging time and the like as a result of the difference in the number of passes for producing the target shape. Even an experienced press operator does not always have an appropriate forging pass schedule. Further, conventionally, the dimension measurement of the to-be-wrought material is usually performed at the center in the longitudinal direction of the to-be-wrought material, that is, every time after the end of the one-pass forging process or after the end of the two-pass forging process. Since only one part of the part was measured using a dimension measuring tool such as a press gauge, there was a problem that the variation in the shape of the entire stretched material in the longitudinal direction was large.

For forging work using a free forging press, for example, Patent Document 1 discloses a bar forging method. This bar forging method is almost vertically and horizontally symmetrical at the final stage of forging when forging a regular octagonal cross section from any steel ingot for the purpose of shortening forging time and ensuring accuracy. This is a method of forming a regular octagonal cross section having a predetermined dimension by forming four rectangular cross-sections or octagonal cross-sectional shapes, and then reducing the directions by four passes. Further, for example, in Patent Document 2, a material flow is predicted by forging simulation based on measured mold shape data, material shape data, and molding condition data, and molding defects and molding are determined based on the material flow prediction. A quality prediction system for forged products that performs analysis such as accuracy is disclosed.
JP 63-326332 A JP 2005-238289 A

  However, the bar forging method disclosed in Patent Document 1 has a deformation behavior obtained experimentally in advance, for example, in the process of forging from a steel ingot having a square cross section to a regular octagonal cross section. It is necessary to calculate the shape for each pass (reduction) using the prediction formula. Further, forging from the steel ingot to a quadrangular target shape immediately before forging into a regular octagon is not specifically described. In addition, as for the forging method from a steel ingot having a quadrangular cross-sectional shape to a target shape having a quadrangular shape, various methods have conventionally existed, but forging cannot be performed according to the target shape, that is, according to the design value. The dimensions were off. On the other hand, in the quality prediction system for forged products disclosed in Patent Document 2, since the three-dimensional analysis is performed, the analysis cost is increased and the analysis time is also required, so that it is difficult to apply to the actual press.

  Therefore, the subject of the present invention is a forging process in which a steel bar is formed into a shaft material such as a round bar by free forging. Regardless of the experience of the press operator, the reduction amount and the feed amount are calculated by simple calculation. Forging process using this process design system, which determines the machining conditions such as target shape and can accurately obtain the final quadrilateral shape before the final octagonal shape of the workpiece It is an object of the present invention to provide a method and a forging apparatus that can reduce dimensional variations in the longitudinal direction of a workpiece.

  In order to solve the above problems, the present invention employs the following configuration.

  The process design system for forging processing according to claim 1 alternately repeats the operation of lowering the working material from two opposing directions perpendicular to the axial direction and the feeding operation in the axial direction. A forging process design system that forges into a square shape or a final octagon shape through a final quadrangular shape, and then finishes the shaft material. The process design system is based on the cross-sectional shape of the product shaft material. Step 1 for determining the final quadrangular shape and final octagonal shape size, the number of passes from the steel ingot to the final square shape size, and the target shape size (height and width) in each pass are determined and reduced. Step 2 for setting the amount and feed amount, Step 3 for measuring the height and width of the to-be-wrought material for each required pass, and comparing the measurement results with the target dimensions of the to-be-wrought material, Pressure for target geometry after pass Characterized by comprising the steps 4 to modify the amount and feed rate.

In the step design system for forging processing according to claim 2, the final square shape dimensions (one side DS) and 8 for forging from the final quadrangular shape to the final octagonal shape in at least four passes in the step 1. The square shape dimension (opposite side dimension H) is calculated using the following formulas (1) and (2).
DS = SQRT (δ × β × π × (DF) 2/4) --------------------- (1)
DH = SQRT ((β × π × (DF) 2/4) / tan (22.5 °) / ² ) ------- (2)
Here, DF is the dimension (diameter) of the forged finished material obtained by adding the machining allowance M to the diameter DA of the product shaft (DF = DA + 2M). δ is expressed by δ = 1 / (1−Rt) using the total cross-section reduction rate Rt by at least four passes, and β is the final octagonal shape dimension to the forging finish dimension DF of the product shaft material. Using the cross-sectional reduction rate Rf, β = 1 / (1-Rf)).

  In the forging process design system according to claim 3, the final octagon is obtained by arbitrarily extracting at least two levels of the area increase rate with respect to the cross-sectional area of the forged finished shape of the product shaft material within a range of 5 to 20%. Step S10a for calculating the opposite side dimension DH of the shape, Step S10b for inputting the calculated opposite side dimension DH to the input file of the deformation analysis means, and deformation analysis for finishing the forged finish dimension of the product shaft with the required number of passes. The step S10c is performed, the step S10d of calculating the elongation rate and the cross-sectional area reduction rate of the to-be-wrought material from the deformation analysis result, and the relationship between the elongation rate and the extracted cross-sectional area increase rate is equal to the elongation rate. The final octagonal dimension DH is calculated from step S10e for calculating the cross-sectional area increase rate, and the final octagonal dimension DH is used. And calculates the cross-sectional reduction rate Rt.

  5. The forging process design system according to claim 4, wherein at least two levels of the area increase rate with respect to the cross-sectional area of the final octagonal shape are arbitrarily extracted within a range of 5 to 20%, and one side of the final quadrangular shape is extracted. Step S10f for calculating the respective dimensions DS, Step S10g for inputting the calculated dimensions DS to the input file of the deformation analysis means, and Step S10h for performing deformation analysis forging the final octagonal dimensions in at least four passes. And from step S10i which calculates the elongation rate of a to-be-wrought material from this deformation | transformation analysis result, and the relationship between this elongation rate and the extracted cross-sectional area increase rate, the cross-sectional area increase rate equal to the said elongation rate is calculated. The final square dimension DS is calculated from step S10j, and the sectional reduction rate Rf is calculated using the final square dimension DS. And features.

In the step design system for forging processing according to claim 5, in step 2, an average area reduction rate γm per pass from the material to the final square shape dimension is set, and the steel ingot and final square When the cross-sectional area of the shape is S0 and SN, respectively, two passes are defined as one pass unit U, and an integer obtained by rounding up Nc calculated by the following equation (3) is defined as a total pass unit Ut, and a decrease for each pass unit U. Set the area ratio and determine the target shape dimension of the to-be-wrought material for each pass unit U, and use the following formulas (4) to (11) to determine the height of each pass unit U after the first pass. H1 and width W1 are predicted, and reduction amounts Hf1 and Hf2 in each pass unit U for forging to the target shape dimension are calculated.
Nc = 1/2 × (LOG (SN / S0) / LOG (1-γm)
------- (3)
H1 = H2 * (W2 / (W0 * (H1 / H0) ^-L ) ^F ------------- (4)
W1 = W0 × (H1 / H0) ^-L ----------------------------- (5)
L = 1 + S1 ---------------------------------------------- -(6)
F = 1 + S2 --------------------------------------------- -(7)
S1 = a0 + a1 × (B0 / W0) + a2 × (B0 / W0) ² ---------- (8)
S2 = a0 + a1 × (B1 / H1) + a2 × (B1 / H1) ² ---------- (9)
Hf1 = H0-H1 ----------------------------------------- (10 )
Hf2 = W1-W2 ----------------------- (11 )
Here, H0 and W0 are the height and width of the to-be-worked stretched material on the entry side of the pass unit U, and H2 and W2 are the width and height of the to-be-worked stretched material on the exit side of the pass unit U, H1. Indicates the height of the stretched material after the first pass, B0 and B1 indicate the feed amounts of the pass unit U in the first pass and the second pass, respectively, S1 and S2 indicate the first pass and The width spread coefficient in the second pass is shown. A0 is a constant, and a1 and a2 are coefficients.

In the step design system for forging processing according to claim 6, in step 2, an average area reduction rate γm per pass from the material to the final square shape dimension is set, and the steel ingot and final square When the cross-sectional area of the shape is S0 and SN, respectively, two passes are defined as one pass unit U, and an integer obtained by rounding up Nc calculated by the following equation (3) is defined as a total pass unit Ut, and a decrease for each pass unit U. The surface area is set to determine the target shape dimension of the to-be-wrought material for each pass unit U, and the following formula (3), formula (4a) to (7a), formula (10), and formula (11) are used. Predicting the height H1 and the width W1 after the first pass of each pass unit U, and calculating the reduction amounts Hf1 and Hf2 in each pass unit U for forging to the target shape dimension. To do.
Nc = 1/2 × (LOG (SN / S0) / LOG (1-γm))
------- (3)
H1 = H2 × (W2 / W1) ^−Sa2 -------------------------------- (4a)
W1 = W0 × (H1 / H0) ^-Sa1 --------------------------- (5a)
Sa1 = ζ × (B0 / W0) / (1 + B0 / W0) -------------- (6a)
Sa2 = ζ × (B1 / H1) / (1 + B1 / H1) ------------ (7a)
Hf1 = H0-H1 ----------------------------------------- (10 )
Hf2 = W1-W2 ----------------------- (11 )
Here, H0 and W0 are the height and width of the to-be-worked stretched material on the entry side of the pass unit U, and H2 and W2 are the width and height of the to-be-worked stretched material on the exit side of the pass unit U, H1. Indicates the height of the stretched material after the first pass, B0 and B1 indicate the feed amounts of the pass unit U in the first pass and the second pass, respectively, and Sa1 and Sa2 indicate the first pass, respectively. And the substantial width spread coefficient in the second pass.

  The forging process design system according to claim 7 includes a step S40a for extracting at least three levels of the final square shape dimension, a step S40b for inputting the extracted dimension to an input file of the deformation analysis means, and a material. Step S40c for inputting the friction coefficient selected based on the deformation resistance and the actual machine forging conditions into the input file, Step S40d for calculating the average elongation rate of the to-be-forged material by the analysis means, and the average elongation rate. The constant a0, the coefficients a1 and a2 are obtained from the step S40e using the step S40e for calculating the width spread coefficient S and the step S40f for determining the relationship between the width spread coefficient S and the ratio (B0 / W0) by the least square method. It is characterized by seeking.

  The process design system for forging processing according to claim 8 includes a step S40a for extracting at least three levels of the final square shape dimension, a step S40b for inputting the extracted dimension to an input file of the deformation analysis means, and a material Step S40c for inputting the friction coefficient selected based on the deformation resistance and the actual machine forging conditions into the input file, Step S40d for calculating the average elongation rate of the to-be-forged material by the analysis means, and the average elongation rate. The coefficient ζ is obtained from the step S40e used to calculate the real width spread coefficient Sa and the step 40f which determines the relationship between the real width spread coefficient Sa and the biting ratio (B / W) by regression analysis. And

  The forging process design system according to claim 9 includes the dimensions (height and width) of the to-be-forged material measured in Step 3 and the to-be-developed for each pass unit U determined in Step 2. The reduction amount in the next pass unit U is corrected based on the result of comparing the dimensions (height and width) of the drawn material.

  The shaft forging and stretching method according to claim 10 alternately repeats the operation of rolling the work material from two opposing directions perpendicular to the axial direction and the feeding operation in the axial direction, A shaft forging method forging with a required number of pass units from an initial pass from a steel ingot with 2 passes as 1 pass unit U, using the forging process design system according to claim 4. From the measured dimensions (height and width) of the to-be-worked material of the pass unit U, the amount of reduction for forging to the target shape dimensions (height and width) of the to-be-worked material of the next pass unit U is determined. It was made to do.

  A shaft forging and processing apparatus according to claim 11 is an axial direction using a manipulator and an operation of reducing a processing material by using a plurality of tools from two opposing directions perpendicular to the axial direction. A shaft forging and forging apparatus for forging by alternately repeating the feeding operation to the storage device, wherein the forging and processing apparatus includes a storage device for inputting and outputting the shape of the to-be-forged material, and an input value. A calculation unit for predicting a forged shape of a forged material is provided, and forging is performed by incorporating the forging process design system according to any one of claims 1 to 7. . In addition, it is desirable that the forge processing apparatus is provided with a display device for a reduction amount calculated from an input value and an output value of the shape of the work material to be forged.

  A shaft forging and stretching apparatus according to claim 12, wherein the forging apparatus includes means capable of measuring a width and a height of the to-be-wrought material on the exit side of the tool, and the forged after forging. The dimension of the stretched material is measured, the measured value is held in the storage device, and the amount of reduction in the next pass is determined in conjunction with the travel amount of the manipulator.

  In this invention, in the forging process of the shaft material, the final octagonal shape dimension and the latest final quadrangular shape forged to this final octagonal shape dimension are calculated from the cross-sectional shape of the product shaft material, and from the processing material The number of passes until the final quadrilateral shape is determined, the target reduction amount and the feed amount are set, and two passes from the processing material are taken as one pass unit U. Since the process design system is configured to predict the shape of the to-be-forged material in the next pass unit U and correct the target reduction amount and feed amount by simple calculation using dimensions, the press operator's Regardless of the difference in experience, forging can be performed efficiently, and the forging time required for forging can be shortened as compared with the prior art.

  In addition, a dimensional measurement camera is arranged so that the width and height of the to-be-wrought material after forging on the mold exit side are measured over the entire length. In addition, variation in height dimension can be reduced.

  Embodiments of the present invention will be described below with reference to FIGS. 1 and 10 attached.

FIG. 1 shows a flow of forging work using the process design system for forging work of the embodiment. In Step 1, a steel ingot or the like is used as a processing material, and this processing material is alternately moved in an up-down direction or the like in a direction perpendicular to the axial direction from two opposite directions and in an axial direction. As shown in FIG. 2, after forging from the final quadrangular shape to the final octagonal shape by at least 4 passes, the opposite side dimensions of the final octagonal shape just before finishing the product shaft material such as a round bar by tapping or the like DH and the dimension DS of one side of the final square shape immediately before forging into the final octagon shape are calculated (S10 (S10a to S10j)). That is, if the diameter of the product shaft is D0 and the machining allowance is M, the diameter DF of the forged shaft is DF = D0 + 2M. The opposite side dimension H of the octagonal shape and the one side DS of the final square shape can be obtained by the following equations (1) and (2), respectively.
DS = SQRT (δ × β × π × (DF) 2/4) -------------------- (1)
DH = SQRT ((β × π × (DF) 2/4) / tan (22.5 °) / ² ) ------ (2)
Here, δ is expressed by δ = 1 / (1−Rt) using the total cross-section reduction rate Rt according to the number of passes, and β is the forged finish dimension DF of the product shaft material from the final octagonal shape dimension. Β = 1 / (1−Rf)) using the cross-sectional reduction rate Rf. In addition, the upper limit range of the number of passes in the forging from the final quadrangular shape to the final octagonal shape is usually about 8 to 12 passes.

  Δ and β in the above formulas (1) and (2) can be obtained as follows. FIG. 3 shows the case where the forged finish shape (cross-sectional area A2) of the product shaft material is φ500 mm and the forging (tapping) is performed in the required number of passes, for example, 1 pass from the final 8 shape (cross-sectional area A1). This shows a method for obtaining the optimum value of the octagonal cross-sectional area A1 by deformation analysis using deformation analysis means (three-dimensional deformation analysis software). First, three levels of the area increase rate with respect to the cross-sectional area A2 of the forged finished shape (φ500 mm) are arbitrarily extracted within a range of 5 to 20%, the final octagonal cross-sectional area A1 is determined, and the opposite side dimension DH is calculated. (Step S10a), the calculated opposite side dimension DH is input to the deformation analysis input file (Step S10b), and rotation and reduction are alternately applied to the work stretched material (final octagonal shape) to make one turn. Then, while repeating the operation of feeding in the axial direction, deformation analysis is performed in the case of finishing the forged finish shape in one pass (step S10c). Then, from the deformation analysis result, the elongation rate λ (%) and the cross-sectional reduction rate Re (= (1−A2 / A1) × 100 (%)) of the to-be-drawn material are calculated (step S10d). This calculation result is plotted (three points), and the three plotted points are linearly regressed to obtain a prediction line Pe indicating the relationship between the cross-section reduction rate Re and the elongation λ, and is entered in the figure. Is equal to the elongation rate λ, that is, the optimum value of the cross-sectional reduction rate that satisfies the constant volume condition of the forged material during forging (tapping) is obtained (step S10e), and the forged finish shape is φ500 mm from FIG. In this case, this optimum value is about 9%. The optimum value of the cross-section reduction rate is the optimum value of the area increase rate of the final octagonal shape with respect to the forged finished shape (A1 = A2 / (1-0.09)). That is, the optimum value of the cross-section reduction rate Re is the cross-section reduction rate Rf from the final octagonal shape dimension to the forging finish dimension DF of the product shaft, and the coefficient β is obtained by β = 1 / (1−Rf). be able to. Therefore, when the forged finish shape is φ500 mm, β = 1 / (1−0.09) ≈1.1. The opposite octagonal length DH of the final octagonal shape is calculated from the optimum area A1 of the final octagonal shape increased by the optimum area increase rate with respect to the cross-sectional area A2 of the forged finish shape, and the final octagonal shape is calculated. Can be determined geometrically. The required number of passes from the final 8 shapes (cross-sectional area A1) to the forged finish shape (cross-sectional area A2) is at most about 2 to 3 passes.

  FIG. 4 shows the final quadrilateral shape when forging the final octagonal shape (cross-sectional area A0) from the final octagonal shape (cross-sectional area A0) to the final octagonal shape in at least four passes, when the opposite octagonal length DH is 500 mm. 3 shows a method for obtaining the optimum value of the cross-sectional area A0 by deformation analysis using deformation analysis means (three-dimensional deformation analysis software) as in the case shown in FIG. First, the area increase rate with respect to the cross-sectional area A1 of the final octagonal shape (opposite side dimension DH = 500 mm) is arbitrarily extracted at four levels within a range of 5 to 20% to determine the final quadrangular cross-sectional area A0. Each side dimension DS is calculated (step S10f), the calculated one side dimension DS is input to the deformation analysis input file (step S10g), and the work stretched material (final square shape) is fed. 2 or more of the tool width (anvil width), as shown in FIG. 2, the longitudinal (diagonal) reduction is performed over the entire length of −90 ° rolling and the lateral reduction is performed over the entire length of −90 ° rolling longitudinal. Deformation analysis is performed in the case where the final octagonal shape is finished under four-pass pressure in which directional reduction is performed over the entire length and -90 ° rolling lateral reduction is performed over the entire length (step S10h). Then, from this deformation analysis result, the elongation rate λ (%) and the cross-section reduction rate Re (= (1-A1 / A0) × 100 (%)) of the to-be-drawn material are calculated (step S10i). This calculation result is plotted (four points), and the four plotted points are linearly regressed to obtain a prediction line Pe indicating the relationship between the cross-section reduction rate and the elongation λ. An optimum value of the cross-section reduction rate that is equal to the elongation rate λ, that is, satisfies the constant volume condition of the to-be-forged material during forging (forging) (step S10j). From FIG. 4, when the opposite side dimension DH of the final octagonal shape is 500 mm, this optimum value is about 12%. The optimum value of the cross-section reduction rate Re becomes the optimum value of the area increase rate of the final quadrangular shape with respect to the final octagonal shape (A0 = A1 / (1-0.12)). That is, the optimum value of the cross-section reduction rate is the cross-section reduction rate Rt in the process of forging from the final square shape dimension to the final octagon shape under at least four-pass pressure, and the coefficient δ is δ = 1 / (1-Rt). Accordingly, when the opposite side dimension DH of the final octagonal shape is 500 mm, δ = 1 / (1−0.12) ≈1.12. The length DS of one side of the final quadrangular shape is geometrically calculated from the optimal area A0 of the final quadrangular shape that is increased by the optimal area increase rate with respect to the cross-sectional area A1 of the final octagonal shape. Then, the dimensions of the final square shape can be determined.

  As described above, the coefficients δ and β in the equations (1) and (2) can be determined. The coefficients δ and β vary depending on the forged finished size of the product shaft material and the dimensions of the final octagonal shape and final quadrangular shape associated therewith, but are usually in the range of 1 to 1.5. Further, the final quadrangular shape to the final octagonal shape is usually formed by four passes, and the reduction amount S (i) in each pass is a value of about 10 to 50% of the dimension DS of one side of the final quadrangular shape. (Ks (i) = 0.1 to 0.5), the feed amount B (i) is about 10 to 100% of the dimension DS (kb (i) = 0.1 to 1.0). Each is set (i: path No.). In addition, the deformation resistance of the to-be-drawn material used in the deformation analysis is a material in which the material (steel type), processing temperature, strain, and strain rate dependency are clarified using a compression test or the like. In addition, the material temperature distribution used for the deformation analysis is calculated by a heat transfer calculation formula verified by actual machine measurement values. The same applies to the following deformation analysis.

Next, in step 2, the number of passes from the processing material to the final quadrangular shape is determined (S20). An integer obtained by setting an average area reduction rate γm in all passes from the processing material (cross-sectional area S0) to the final square shape (cross-sectional area SN) and rounding up Nc calculated by the following equation (3) Let Nu be the total path unit Ut.
Nc = 1/2 × LOG (SN / S0) / LOG (1-γm) -------- (3)
Normally, the number of passes (total number of passes) N (= 2 × Nu) is an even number. When this number of passes N is determined, two passes from the initial pass (first pass) from the processing material are defined as one pass unit U. The area reduction rate Ru (i) (i = 1 to Nu) for each pass unit U is determined. The area reduction rate Ru (i) for each pass unit U can be determined according to the shape of the product shaft. When the product shaft is, for example, a round bar, the surface reduction rate Ru (i) is determined so as to decrease linearly with an increase in the pass unit based on the forging performance data (see FIG. 5A). ). Further, when the product shaft is a square material such as mold steel, it is necessary to reduce the amount of reduction in order to form a square shape as it approaches the product shape. Therefore, as shown in FIG. 5B, the surface reduction rate Ru (i) is determined so as to decrease in a quadratic curve as the number of pass units increases based on the forging performance data. Further, when it is necessary to close the internal defect, it is desirable to increase the area reduction rate in the initial forging process, so that the area reduction rate Ru (i) is as shown in FIG. Then, based on the forging performance data, it is determined to decrease exponentially. In this way, when the area reduction rate Ru (i) of each pass unit U is determined, the cross-sectional areas Su1 and Su2 of the to-be-worked stretched material on the entry side and the exit side of each pass unit U can be calculated. As shown in FIG. 6, the first pass of each pass unit U is “square corner → rectangular corner”, and the second pass is trained in a pass schedule in which the opposite is “rectangular corner → square corner”. If stretching is performed, the cross-sectional area Su1 = H0 × W0 (H0≈W0) and the cross-sectional area Su2 = H2 × W2 (H2≈W2) on the exit side are obtained. The dimensions H0, W0 and H2, W2 of the to-be-wrought material can be set. In addition, when the initial shape (material shape) is a square or rectangular quadrangular shape and the cross-sectional shape of the product shaft material is a square or rectangular quadrangular shape, such as steel for molds, as described above, Even if the cross-sectional areas Su1 and Su2 on the entry side and the exit side of the pass unit U are not obtained, the target dimension of each pass pass unit U linearly decreases the length of one side of the square for each pass unit U. It can also be determined by. Further, in FIGS. 5A to 5C, the dimension of the stretched material can be displayed as the vertical axis instead of the cross-sectional area.

  The dimension of the to-be-wrought material in step 3 is determined by measuring the height H2 and width W2 of the to-be-wrought material on the exit side of each pass unit U by using a hot path measuring tool, a CCD or a CMOS image sensor. It can be measured by a camera, a laser dimension measuring device, a press stroke measuring device, or the like (S30).

  Next, in step 4, the feed amounts in the first and second passes of dimensions H0, W0 and H2, W2 of the to-be-worked stretched material for each pass unit U obtained in step 2 above. Using B0 and B1, the height H1 and the width W1 of the to-be-forged material after the first pass can be predicted as follows (S40 (S40a to S40f)). In addition, as said feed amount B0 and B1, normally, in the upstream of the forge processing process (pass unit U close to a raw material), the quantity substantially equal to the tool (die) width to reduce is the middle of the forge process. Then, the amount of about half of the tool width is changed in accordance with the product shaft on the downstream side (pass unit U close to the product shaft), and the amount of about 1/2 to 1/5 of the tool width is Used.

Generally, in the forging in the forging process, the relationship of Expression (12) is established.
W1 / W0 = (H1 / H0) ^-L ----------------------------- (12)
L = 1 + S1 ---------------------------------------------- (6)
S1 = a0 + a1 × (B0 / W0) + a2 × (B0 / W0) ² -------- (8)
From formula (12), the width W1 of the to-be-forged material after the first pass is
W1 = W0 × (H1 / H0) ^-L ---------------------------- (5)
On the other hand, the height H2 of the stretched material after the second pass is the same as the formula (12).
H2 = H1 × (W2 / W1) ^-F ------------------------------ (13)
F = 1 + S2 --------------------------------------------- -(7)
S2 = a0 + a1 × (B1 / H1) + a2 × (B1 / H1) ² --------- (9)
From equation (12) and equation (13), if W1 is deleted,
H2 = H1 × (W2 / (W0 × (H1 / H0) ^−L ) ^−F −−−−−−−−−−−− 14)
From equation (14)
H1 = H2 * (W2 / (W0 * (H1 / H0) ^-L ) ^F ------------- (4)
As can be seen from Expression (7) and Expression (9), Expression (4) includes H1 in the index F on the right side, but the solution (H1) can be obtained by numerical calculation. Substituting this H1 into equation (5), the width W1 of the to-be-forged material after the first pass can be calculated, and the dimensions H2 and W2 on the exit side (after the second pass) of the pass unit U are satisfied. The dimensions H1 and W1 after the first pass can be calculated. The constants a0 and the coefficients a1 and a2 in the equations (8) and (9) can be obtained as follows by deformation analysis using deformation analysis means (three-dimensional deformation analysis software).

First, the dimension of one side DS of the final square shape of the stretched material is extracted from three levels (three dimensions) or more within the actual machine operating range (for example, DS = 500 mm) (step S40a), and the deformation Input to the input file of the analysis means (step S40b), and further, the deformation resistance of the material (forged stretched material) and the shape of the material (forged stretched material) and the tool as proposed in Japanese Patent Application No. 2006-203622 The friction coefficient selected based on the actual machine forging conditions such as the amount of reduction by (anvil) and the feed amount of the material (forged material) is input to the input file (step S40c). And the average elongation rate (lambda) of a raw material (wrought material) is calculated | required by the said deformation | transformation analysis means (step S40d). This elongation (elongation) rate λ can be obtained by attaching a standard line for measuring elongation in advance to the material (forged stretched material) and measuring the amount of elongation of the standard line after reduction. That is,
λ = L1 / L0 ------------------------------------------ (15 )
Here, L0: initial length of the standard line (before forging), and L1: length of the standard line after forging.

As described above, generally, in the forging in the forging process, the relationship of Expression (12) is established.
W1 / W0 = (H1 / H0) ^-L ----------------------------- (12)
L = 1 + S1 ---------------------------------------------- (6)
S1 = a0 + a1 × (B0 / W0) + a2 × (B0 / W0) ² -------- (8)
S1 in the above formula (8) corresponds to the width expansion coefficient S in the first pass during flat forging, that is, forging in the forging process, and the width expansion coefficient S is the width of the to-be-forged material on the pass entrance side. A quadratic expression using as a variable the ratio of the feed amount B (feed amount B0 in the first pass) to W (width W0 on the entry side of the pass unit U in the first pass), that is, the biting ratio (B / W). It is known from the experiment of forge processing (flat forging) using carbon steel (for example, refer nonpatent literature 1). In the second pass of the pass unit U, as shown in FIG. 6, the width W on the pass entry side is the height H1 after the first pass, so the biting ratio B / W is B1 / H1. .
A. Tomlinson, A. Met et al .: Journal of the Iron and Steel Institute, Vol. 193 (1959), PP.157-162

By replacing the width spread coefficient S1 in the first pass of the above equations (6) and (8) with the width spread coefficient S, L = 1 + S ---------------- ------------------------------- (6b)
S = a0 + a1 × (B0 / W0) + a2 × (B0 / W0) ² --------- (8b)
Therefore, equation (12) is
W1 / W0 = (H1 / H0) ^−1−S = (H1 / H0) ⁻¹ × (H1 / H0) ^−S
--------- (16)
From the condition of a constant volume of the material to be forged during forging (see the first pass in FIG. 6),
L1 x H1 x W1 = L0 x H0 x W0 ------------------------ (17)
From equation (15), equation (16) and equation (17),
λ = L1 / L0 = (H0 × W0) / (H1 × W1) = (W0 / W1) ×
(H0 / H1) = (H1 / H0) ^S ----------------------------- (18)
In equation (18), the elongation λ (= L1 / L0) is known from the deformation analysis, and the height H0 of the to-be-forged material before and after forging (on the entry side and the exit side of the first pass) and H1 is also known. Therefore, the spread coefficient S can be calculated backward using deformation analysis (step S40e).

FIG. 7 shows that the final quadrangular dimension is extracted in the actual machine operating range by 8 dimensions, and the width spread coefficient S obtained from the deformation analysis result for the first pass of the initial pass unit U is set to the biting ratio ( B0 / W0). In the figure, these plots are regressed by a quadratic expression of the biting ratio (B0 / W0) by the least square method to obtain the prediction expression (20) of the width spread coefficient S (step 40f). The prediction line Pe of the width spread coefficient S based on (20) is entered.
S = −0.85 + 0.54 × (B0 / W0) −0.080 × (B0 / W0) ²
-------- (19)
From equation (20), constant a0 = −0.85, coefficient a1 = 0.54, coefficient a2 = −0.080. In this way, the constant a0 and the coefficients a1 and a2 can be determined. These constants a0, coefficients a1 and a2 depend on the material of the to-be-forged material (material). The above-described width spreading coefficient S is a coefficient obtained through the elongation (elongation) rate λ shown in the equation (15) with respect to the reduction amount, and the larger the elongation amount, the smaller the value of the coefficient S. That is, the amount of spread is reduced. Conversely, the smaller the amount of extension, the larger the value of the coefficient S, that is, the amount of width spread becomes larger. Thus, the width spread coefficient S is a coefficient corresponding to the width spread amount of the to-be-wrought material.

Using H1 and W1 obtained from the equations (15) and (5), the target reduction amounts Hf1 and Hf2 in the first pass and the second pass are calculated for each pass unit U as follows. be able to.
Hf1 = H0-H1 ---------- (10)
Hf2 = W1-W2 ---------- (11)
Then, the difference ΔH = H2s−H2a between the height H2a of the to-be-worked material measured in step 3 and the height H2s after the second pass (pass unit U exit side) set in step 2 is obtained. Is larger than a preset value, the height H2a and width W2a of the to-be-forged material measured in step 3 are set as the entry side dimensions H0 and W0 of the next pass unit U, and the above-described H0 and W0 The dimensions H1 and W1 after the first pass in the next pass unit U are calculated from the outgoing side dimensions H2 and W2 of the next pass unit U set in advance as described above, and the expressions (16) and (17) are calculated. Thus, the amount of reduction in the next pass unit U is recalculated and forging is performed so as to realize this amount of reduction. Thereafter, the forging process is continued to the final quadrangular shape while repeating the correction of the target reduction amount Hf1 based on the dimensions of the to-be-forged material measured for each pass unit U. When the product shaft is in the shape of a shaft, such as a round bar, the final quadrangular corners (four corners) are alternately squeezed diagonally, and the final octagonal shape is usually formed in four passes. After that, it is finished into a product shaft.

  Table 1 shows the forging time and yield from the raw material to the product shaft when forging from a processing material (steel ingot) having a cross-sectional shape of Φ1000 mm to a product shaft (round bar) having a cross-sectional shape of Φ500 mm. In the case of the forging method using the forging machine incorporating the process design system of the present invention (Example), the press operator has experienced using the forging machine not incorporating this process design system. The results of comparison are shown for the case where the forging process is performed by (Comparative Example). Table 2 shows constants a0 and coefficients a1 and a2 of the equations (8) and (9) when the process design system of the present invention is used. In addition, as the height H0 and the width W0 of the processing material (Φ1000 mm), a dimension of one side of a square having the same cross-sectional area as Φ1000 mm (H0 = W0 = 886 mm) was used.

  From Table 1, in the case of the comparative example that does not use the above process design system, the number of passes from the material to the final quadrilateral shape is large, and the final quadrilateral shape is also a distorted shape. As a result of the increased number of passes, the forging time is 60 minutes, whereas in the case of the embodiment by the forging method using the above-described process design system, from the material to the final rectangular shape, the final rectangular shape to the final shape. As a result of the small number of passes, the forging time is shortened to 45 minutes, the yield is maintained at the conventional level (85%), and an effect of shortening by about 25% is obtained. confirmed.

In addition to the approximation by the quadratic expression shown in the equations (8) and (9), the width spread coefficient S can be obtained with high accuracy as follows. That is, instead of the width spread coefficient, a substantial width spread coefficient Sa in the forging process is defined as follows.
Sa = -ln (W1 / W0) / ln (H1 / H0) ---------------- (20)
From the condition of constant volume of forged material during forge processing,
ln (W1 / W0) + ln (L1 / L0) = − ln (H1 / H0)
---------------- (21)
From equation (20) and equation (21),
ln (L1 / L0) / ln (H1 / H0) =-1 + Sa ----------- (22)
From Equation (20) and Equation (22),
W1 / W0 = (H0 / H1) ^Sa -------------------------------- (23)
L1 / L0 = (H0 / H1) ^1-Sa ------------------------------ (24)
As in the case of the width spread coefficient S, the actual width spread coefficient Sa can be calculated backward from the expression (24) by calculating the elongation rate λ shown in the expression (15) using the deformation analysis result. The substantial width spread coefficient Sa is also expressed as a function of the biting ratio B / W, and the width spread coefficient S (S1 or S2) has a relationship of Sa = 1 + S.

FIG. 8 shows the dimensions of the final quadrangular shape extracted by 9 dimensions within the actual machine operating range, and obtained from the deformation analysis results for the first pass of the initial pass unit U, as in the case shown in FIG. The width spread coefficient Sa is plotted against the biting ratio (B0 / W0). In the figure, a prediction line Pae of the actual width spread coefficient Sa obtained from a prediction formula (25a) of the actual width spread coefficient Sa described later is shown. Here, when the biting ratio B / W = 1, it is considered that the substantial width spreading coefficient Sa and the elongation coefficient (1−Sa) (the index on the right side of Expression (24)) are equal, and therefore Sa = 1−Sa. Therefore, Sa = 1/2. Further, when the biting ratio B / W is very small, no widening occurs, so W1 / W0 = 1 to Sa = 0. Further, when the biting ratio B / W is very large, the elongation (elongation) is eliminated, so that the elongation coefficient 1-Sa = 0 to Sa = 1. The simplest function form of the function Sa = F (B / W) satisfying these extreme states is expressed by the following equation (25).
Sa = ζ × (B / W) / (1 + B / W) ------------------------- (25)
Here, ζ is a coefficient (constant) obtained by data regression. When the data of the biting ratio and the substantial width spread coefficient Sa shown in FIG. 8 is regressed by regression analysis, for example, by the least square method to obtain the coefficient ζ, ζ = 1.216. Therefore, the prediction formula of the substantial width spread coefficient Sa is determined as follows.
Sa = 1.216 × (B / W) / (1 + B / W) ----------------- (25a)
Here, B / W corresponds to B0 / W0 in the first pass of the path unit U and to B1 / H1 in the second pass (see FIG. 6).

  FIG. 9 is a plot of the actual width spread coefficient Sa with respect to the biting ratio B / W obtained from the dimension measurement results of the to-be-forged material in the first pass and the second pass of the 1-pass unit U in an actual machine. In the figure, the prediction line obtained from the prediction expression of the equation (25a) is a solid line, and the prediction line obtained from the prediction expression when the real width spreading factor Sa is regressed by a quadratic expression of the biting ratio B / W is a broken line. It showed in. Table 3 shows the correlation coefficient r in the case of the equation (25a) and the quadratic regression described above. In the prediction formula of the substantial width spread coefficient Sa of the equation (25a), as described above, Sa = 0 when the biting ratio B / W≈0 and Sa = 1 when B / W≈1, taking into account the extreme state. Therefore, the correlation coefficient r is larger than the prediction formula based on the quadratic regression, and the prediction formula is more accurate.

  Even in the above-described manner, the substantial width spread coefficient Sa can be predicted. From the substantial width spread coefficient Sa and the elongation (elongation) ratio λ (= L1 / L0), the path unit can be calculated by the above equation (24). The height H1 of the forged material after the first pass of U can be obtained. And the width W1 of the to-be-forged material after the 1st pass can be calculated | required by substituting the height H1 of this to-be-forged material into said Formula (23). Therefore, the target reduction amounts Hf1 and Hf2 can be accurately calculated for each pass unit U by using the height H1 and the width W1.

Note that an average area reduction rate γm in all passes from the processing material (cross-sectional area S0) to the final square shape (cross-sectional area SN) is set, and Np calculated by the following equation (3a) is rounded up. The total number of passes is N, and instead of the above-mentioned two passes as one pass unit U, the cross-sectional area is obtained for each pass as shown in FIGS. It is also possible to calculate the amount of reduction by determining the dimensions.
Np = LOG (SN / S0) / LOG (1-γm) ---------- (3a)
The determination of the target dimension for each pass is usually performed on the downstream side of the forging process (pass side close to the product shaft) in order to forge accurately into the final quadrangular shape. Using the dimensions (height and width) measured for each pass, the determined target dimension, that is, the reduction amount can be corrected.

  FIGS. 10A and 10B schematically show the forging apparatus according to the embodiment. As shown in FIG. 10 (a), the molds 2 and 2 which are tools for reducing the working material, that is, the to-be-shaped material 1 from two opposite directions perpendicular to the axial direction of the work material. Line sensor cameras 3 and 4 using a CCD image sensor, which are means capable of measuring the width W and height H of the stretched material 1 on the exit side, are sensor mounting portions (not shown) of the forging apparatus. Is installed. As shown in FIG. 10B, the measurement results of the width W and the height H by the cameras 3 and 4 are as follows. Along with the travel amount Tm of the manipulator 5 that draws out in the forging process direction, it is taken into the storage device 6 of the computer that controls the forging process. The storage device 6 stores the components of the process design system described above. Using the measured data of the width W and height H of the to-be-worked stretched material 1 and the travel amount Tm data of the manipulator 5 measured on the exit side of the molds 2 and 2, that is, immediately after the reduction, the calculation device 7 of the computer The amount of reduction at each position in the longitudinal direction of the stretched material 1 can be calculated. Specifically, the measurement data of the width W and the height H and the travel amount Tm of the manipulator 5 are linked, that is, associated with each other and stored in the storage device 6 so that the overall shape of the work stretchable material 1 is grasped. can do. The measurement data of the height H becomes a constant value depending on the reduction (interval) setting of the molds 2 and 2, but the measurement data of the width W changes in the longitudinal direction of the work stretched material 1 because the amount of reduction is different. To do. In this way, in the second pass of the pass unit U that rotates the to-be-shaped material 1 as the next pass by 90 ° and reduces the width W (W1) (see FIG. 6), the width W of the to-be-shaped material 1 Further, by storing and holding the measurement data of the height H and the travel amount Tm of the manipulator 5 in association with each other, the travel amount Tm of the manipulator 5 is set with respect to the target shape (height H and width) in this next pass. By operating, that is, by operating the amount of biting into the molds 2 and 2, the reduction adjustment can be performed manually or automatically for each position in the longitudinal direction of the stretched material 1. Thereby, the dimensional variation of the width W and the height H can be reduced over the entire length of the stretchable material 1. And the dimension of width W and height H with few variations can be used as measurement data on the exit side of each pass unit U in the above-described process design system. As the cameras 3 and 4, a camera using a CMOS image sensor may be used, and not only a line sensor camera in which image sensors are arranged one-dimensionally but also a camera arranged in two dimensions can be used.

It is explanatory drawing which shows the flow of the forging process using the process design system of embodiment. It is explanatory drawing which shows typically from the last square shape of forge processing to a forge finishing shape. It is explanatory drawing which shows the method of calculating | requiring the optimal cross-sectional area of a final octagon shape. It is explanatory drawing which shows the method of calculating | requiring the optimal cross-sectional area of the last square shape. (A)-(c) It is explanatory drawing which shows typically the method of determining the cross-sectional area of the to-be-forged stretch material of each pass unit U in the process design system of embodiment. FIG. 6 is an explanatory diagram schematically showing a deformed state of a first pass and a second pass in each pass unit U. It is explanatory drawing which shows the relationship between the breadth spreading coefficient S and biting ratio B0 / W0. It is explanatory drawing which shows the relationship between the substantial width expansion coefficient Sa and the biting ratio B0 / W0. It is explanatory drawing which shows the relationship between the real breadth coefficient Sa based on real machine data, and the biting ratio B / W. (A) It is explanatory drawing (perspective view) which shows typically the forge processing apparatus of embodiment. (B) Same as above (side view)

Explanation of symbols

DESCRIPTION OF SYMBOLS 1, 1a-1c: Wrought material 2: Die 3, 4: Line sensor camera 5: Manipulator 6: Storage device 7: Arithmetic device

Claims (12)

  The operation of rolling down the processing material from two opposite directions perpendicular to the axial direction and the feeding operation in the axial direction are repeated alternately to obtain the final quadrangular shape or the final quadrangular shape and the final 8 A forging process design system for finishing a shaft after forging into a square shape, wherein the process design system determines the final square shape and final octagon shape dimensions from the cross-sectional shape of the product shaft 1, step 2 for determining the number of passes from the steel ingot to the final quadrangular shape and the target shape dimensions (height and width) in each pass and setting the amount of reduction and feed, and for each required pass Step 3 for measuring the height and width of the to-be-drawn material, and comparing the measurement result with the target size of the to-be-drawn material, and correcting the reduction amount and feed amount for the target shape size after the next pass. Having step 4 Process Planning System extend forging process, characterized. In step 1, the final square shape dimension (one side DS) and the octagonal shape dimension (opposite side dimension DH) for forging from the final square shape to the final octagonal shape in at least four passes are expressed by the following formula ( The forging process design system according to claim 1, which is calculated using 1) and formula (2).
DS = SQRT (δ × β × π × (DF) 2/4) -------- (1)
DH = SQRT ((β × π × (DF) 2/4) / tan (22.5 °) / ² ) ------- (2)
Here, DF is the dimension (diameter) of the forged finished material obtained by adding the machining allowance M to the diameter DA of the product shaft (DF = DA + 2M). δ is represented by δ = 1 / (1−Rt) using the total cross-section reduction rate Rt according to the number of passes, and β is a cross section from the final octagonal shape dimension to the forging finish dimension DF of the product shaft. Using the reduction rate Rf, it is expressed by β = 1 / (1−Rf)).   Step S10a for calculating the opposite side dimension DH of the final octagonal shape by extracting at least two levels of the area increase rate with respect to the cross-sectional area of the forged finished shape of the product shaft, respectively, Step S10b, in which the calculated opposite side dimension DH is input to the input file of the deformation analysis means, step S10c, in which a deformation analysis is performed to finish the forged dimensions of the product shaft with the required number of passes, From step S10d for calculating the elongation rate and the cross-sectional area reduction rate of the material, and from step S10e for calculating the cross-sectional area increase rate equal to the elongation rate from the relationship between the elongation rate and the extracted cross-sectional area increase rate, the final 8 A rectangular dimension DH is calculated, and the cross-sectional reduction rate Rt is calculated using the final octagonal dimension DH. Process Planning System extend forging process according to claim 2.   The step S10f of calculating at least two levels of the area increase rate with respect to the cross-sectional area of the final octagonal shape within a range of 5 to 20% to calculate the dimension DS of one side of the final quadrangular shape, and this calculation. Step S10g for inputting the dimension DS to the input file of the deformation analysis means, Step S10h for performing deformation analysis forging into the final octagonal dimension in at least four passes, and the elongation rate of the to-be-forged material from this deformation analysis result From the relationship between the step S10i for calculating the cross-sectional area and the extracted cross-sectional area increase rate, the final square dimension DS is calculated from the step S10j for calculating the cross-sectional area increase rate equal to the elongation rate. 4. The forging according to claim 2, wherein the cross-section reduction rate Rf is calculated using the final square-shaped dimension DS. 5. Processing of the process design system. In Step 2, when an average area reduction rate γm per pass from the material to the final square shape dimension is set, and the cross-sectional areas of the steel ingot and the final square shape are S0 and SN, 2 Assuming that a pass is one pass unit U, an integer obtained by rounding up Nc calculated by the following equation (3) is a total pass unit Ut, and a surface area reduction rate is set for each pass unit U, and the toughening elongation for each pass unit U. The target shape dimension of the material is determined, the height H1 and the width W1 after the first pass of each pass unit U are predicted using the following formulas (4) to (11), and the target shape dimension is forged. The forging process design system according to any one of claims 1 to 4, wherein the rolling reduction amounts Hf1 and Hf2 in each pass unit U for stretching are calculated.
Nc = 1/2 × (LOG (SN / S0) / LOG (1-γm))
------- (3)
H1 = H2 * (W2 / (W0 * (H1 / H0) ^-L ) ^F ------------- (4)
W1 = W0 × (H1 / H0) ^-L ----------------------------- (5)
L = 1 + S1 ---------------------------------------------- -(6)
F = 1 + S2 --------------------------------------------- -(7)
S1 = a0 + a1 × (B0 / W0) + a2 × (B0 / W0) ² ---------- (8)
S2 = a0 + a1 × (B1 / H1) + a2 × (B1 / H1) ² ---------- (9)
Hf1 = H0-H1 ----------------------------------------- (10 )
Hf2 = W1-W2 ----------------------- (11 )
Here, H0 and W0 are the height and width of the to-be-worked stretched material on the entry side of the pass unit U, and H2 and W2 are the width and height of the to-be-worked stretched material on the exit side of the pass unit U, H1. Indicates the height of the stretched material after the first pass, B0 and B1 indicate the feed amounts of the pass unit U in the first pass and the second pass, respectively, S1 and S2 indicate the first pass and The width spread coefficient in the second pass is shown. A0 is a constant, and a1 and a2 are coefficients. In Step 2, when an average area reduction rate γm per pass from the material to the final square shape dimension is set, and the cross-sectional areas of the steel ingot and the final square shape are S0 and SN, 2 Assuming that a pass is one pass unit U, an integer obtained by rounding up Nc calculated by the following equation (3) is a total pass unit Ut, and a surface area reduction rate is set for each pass unit U, and the toughening elongation for each pass unit U. The target shape dimension of the material is determined, and the height of each pass unit U after the first pass is calculated using the following formulas (3), (4a) to (7a), (10), and (11). The forging according to any one of claims 1 to 4, characterized in that the reduction amounts Hf1 and Hf2 in each pass unit U for predicting H1 and the width W1 and forging to the target shape dimension are calculated. Processing process design system.
Nc = 1/2 × (LOG (SN / S0) / LOG (1-γm))
------- (3)
H1 = H2 × (W2 / W1) ^−Sa2 -------------------------------- (4a)
W1 = W0 × (H1 / H0) ^-Sa1 --------------------------- (5a)
Sa1 = ζ × (B0 / W0) / (1 + B0 / W0) -------------- (6a)
Sa2 = ζ × (B1 / H1) / (1 + B1 / H1) ------------ (7a)
Hf1 = H0-H1 ----------------------------------------- (10 )
Hf2 = W1-W2 ----------------------- (11 )
Here, H0 and W0 are the height and width of the to-be-worked stretched material on the entry side of the pass unit U, and H2 and W2 are the width and height of the to-be-worked stretched material on the exit side of the pass unit U, H1. Indicates the height of the stretched material after the first pass, B0 and B1 indicate the feed amounts of the pass unit U in the first pass and the second pass, respectively, and Sa1 and Sa2 indicate the first pass, respectively. And the substantial width spread coefficient in the second pass.   Step S40a for extracting at least three levels of the final square shape dimension, Step S40b for inputting the extracted dimension to the input file of the deformation analysis means, and the friction coefficient selected based on the deformation resistance of the material and the actual forging conditions To the input file, step S40d for calculating the average elongation rate of the to-be-wrought material by the analyzing means, step S40e for calculating the width expansion coefficient S using the average elongation rate, 6. The forging according to claim 5, wherein the constant a0, the coefficients a1 and a2 are obtained from the step 40f for determining the relationship between the width spread coefficient S and the ratio (B0 / W0) by the least square method. Processing process design system.   Step S40a for extracting at least three levels of the final square shape dimension, Step S40b for inputting the extracted dimension to the input file of the deformation analysis means, and the friction coefficient selected based on the deformation resistance of the material and the actual forging conditions To the input file, step S40d for calculating the average elongation rate of the to-be-wrought material by the analyzing means, step S40e for calculating the width expansion coefficient S using the average elongation rate, The forging process design system according to claim 6, wherein the coefficient ζ is obtained from step 40 f in which a relationship between the spread coefficient S and the biting ratio (B / W) is determined by regression analysis.   Results of comparing the dimensions (height and width) of the to-be-wrought material measured in Step 3 and the dimensions (height and width) of the to-be-wrought material on the exit side of each pass unit U determined in Step 2 9. The forging process design system according to claim 5, wherein the amount of reduction in the next pass unit U is corrected based on the above.   The processing material is alternately lowered from two opposing directions perpendicular to the axial direction, and the feeding operation in the axial direction is repeated alternately, and from the initial pass forging the material, two passes are made into one pass unit. A method of forging a shaft material forged with a required number of pass units as U, the dimension of the to-be-forged material of the pass unit U measured using the forging process design system according to claim 4 ( A shaft material characterized by determining a reduction amount and a feed amount for forging to a target shape dimension (height and width) of a to-be-stretched material of the next pass unit U from a height and a width) Forging process.   A shaft material that is forged by alternately repeating the operation of reducing the material for processing from two opposing directions perpendicular to the axial direction using a plurality of tools and the feeding operation in the axial direction using a manipulator. A forging device, wherein the forging device inputs and outputs the shape of the to-be-forged material, and an operation for predicting the forged shape of the to-be-forged material from the input value. 10. A shaft forging and processing apparatus comprising: a forging process incorporating the forging process design system according to any one of claims 1 to 9.   The forging device includes means capable of measuring the width and height of the to-be-forged material on the exit side of the tool, measures the dimensions of the to-be-forged material after forging, and stores the measured values in the memory 12. The shaft forge processing apparatus according to claim 11, wherein the shaft is forged and held in an apparatus, and the amount of reduction in the next pass is determined in conjunction with the travel amount of the manipulator.

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