Analysis on a flexible forging cell

113-122Forging and pressing in manufacturing industry has not been adapted to flexible manufacturing systems (FMS). Predictions on the metal flow and required power have been made here through the upper bound analysis by applying various amounts of deformation in an incremental manner. In order to observe the final dimensions and the structural changes during open die forging, the 6082 aluminium billets (annealed at 425°C for two hours and cooled in the air) have been subjected to cold deformation between simple flat tools. The TEM observations have been made for different parts of the locally deformed aluminium billets to show dislocation behaviour during multi-cycle cold open die forging process.Formation of a flexible forging cell (FFC), as an initial step to FMS is also described here. A simple control system is proposed to enable a communication link between computer, press and robot arm. The robot arm manipulates workpiece between upper and lower dies, where fixed on the press, to run multi compression and rotation cycles in forging of simple rectangular and square cross-section components