FORGING FUTUREFORGE
integration, will improve the AFRC’s predictive
power and accelerate the development of
high integrity forged products.
The facility aims to be not too big to allow
affordable data gathering, but not too small
to prevent the capture of critical behaviour, to
establish data-driven process development.
The provision of greater quantities of more
representative data through FutureForge will
enable future models that are predictive in
more quantitative terms.
Perez believes it will “breathe new life into
the forging supply chain” and help provide a
deeper understanding of products and
processes, boosting ef ciency and
competitiveness.
“This programme will provide a state-of-the
art platform for data gathering and connectivity,
allowing the digitization of hot forging to be
tested and validated,” says Perez.
The AFRC feels that by combining digital
technologies will all three forging modes and
supplementing this capability with its own
capabilities: material characterisation,
residual stress, metrology and modelling
expertise, it will be able to better understand
the subtleties of each processing method.
FutureForge will provide a range of
technical capabilities from each of the hot
forging processes that will be carried out on
the tri-modal 2,000-ton hydraulic press.
“The hot forging platform includes a
bespoke tri-modal industry demonstrator; high
accuracy manipulator; two industrial furnaces;
data capture, connectivity and security; and
high temperature die capability,” notes Perez.
The open die processing will be able to
meet a maximum load of 12,000 kN, at a
working speed of 15-92 mm/s, approach
speed of 50-220 mm/s with a maximum die
temperature of 600°C.
Closed die forging will have the capability
of handling a maximum load of 20,000 kN, at
a working speed of 1-25 mm/s, approach
speed of 50-220 mm/s with a maximum die
temperature of 700°C.
Isothermal forging will be up to a
maximum load of 20,000 kN, at a working
speed of 0.04-1 mm/s, approach speed of
20-50 mm/s and a maximum die
temperature of 1300°C.
RESEARCH PROGRAMME
As part of the opening of the new facility at
the AFRC, a FutureForge Research
FutureForge programme
leader Marcos Perez says there will be three modes of operation
under one single platform – open die forging, closed die forging and isothermal forging
Programme has been launched,
encompassing academia, research and
technology institutions and industrial
organisations, harnessed by the existing
expertise of the AFRC and the wider NMIS.
This R&D activity will help to develop and
enhance forging processes, improving quality
and ef ciency for the next generation of
materials and components and the
requirements that they must meet.
Perez explains that a major part of this
programme will be the strong collaboration
with Tier 1 and Tier 2 partner members of the
AFRC – who come from different sectors and
parts of the forging supply chain.
One of the main objectives he notes, is to
develop capabilities on three modes of
operations – open die forging, closed die
forging and isothermal forging and digital
manufacturing.
The programme will investigate isothermal
forging capability development and smallscale
research activities will be undertaken
on the microstructural evolution of advanced
materials, under isothermal forging conditions
and the impact on subsequent heat
treatments being carried out.
For closed die forging, the dedicated
heating system on a 500 ton hydraulic press
at FutureForge will have capabilities to heat
dies up to 800°C allowing research on the
dying of materials, coating and lubrication,
and data collection for instrumented preforms
and integration of bre bragg grating sensors
into dies.
Perez says that research into digital
Anastasia Khatuntseva of
the digital team with the
FutureForge model
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