Analysis of Technological Regimes of Open-Die Forging with Model Development for Digital Systems of Metallurgical Production

Contemporary metallurgy requires the efficient production of large-scale components by open-die forging. The paper analyzes the influence of technological parameters (relative bite infeed and relative reduction per pass) on the kinematic (relative elongation) and energy-force (reduced force and reduced work) characteristics of cogging in combined dies. FEM simulations (LS-DYNA) were used for data generation. Based on this data, analytical and high-fidelity AI surrogate models were developed. It is established that both parameters have a monotonic effect on the metrics: narrower infeed maximizes elongation, and reduction determines the absolute load level. The resulting models are intended for embedding in digital twins and automated forging schedule optimization systems.