Optimization of Flash Land Design Through Analysis of the Geometric End Resistance

The production of drop-forged parts requires a complex process design. Due to numerous parameters that influence one another, this is usually carried out through an iterative, FEM-supported process. This process is time- and resource-intensive and requires extensive expert knowledge, which poses significant challenges, particularly for small and medium-sized enterprises (SMEs). At the same time, the process design has a significant impact on production costs, material and energy consumption, and tool life.

The flash path offers considerable potential for optimizing the forging process. Since the flash volume can range from 5 to 200 percent of the component volume depending on the component geometry, optimized design can lead to significant material and cost savings. Although its influence on the forming process is generally known, previous scientific work has focused primarily on individual flash path shapes. The interaction of locally varying flash path geometries has hardly been investigated to date.

The OGAGE research project is therefore investigating how geometric end resistance can be used to systematically design an optimal flash path. The goal is to develop a method that generates an initial flash path design based on component and semi-finished product geometry. This can support the iterative design process and enable targeted control of material flow, thereby reducing material consumption, energy requirements, and tool wear.