General Step Reduction Method for Knowledge-Based Process Planning of Non-Axisymmetrical Forged Products

We propose a process planning method, which is termed the General Step Reduction (GeneSteR) method, for non-axisymmetrical cold- and warm-forged products. The GeneSteR method can produce process plans for non-axisymmetrical forged products without relying on any design cases. The basic principle of the GeneSteR method is to produce reversed forging process plans by reducing the steps that are contained in a forged product by a stepwise approach until a cylindrical billet is obtained. An experimental knowledge base was implemented based on the GeneSteR method and was applied to a universal joint yoke used in automobiles. The experimental results show that the proposed method has sufficient capability to generate satisfactory process plans that include a comparable plan as designed by an experienced engineer in a shorter time.