Design and implementation of a digital infrastructure for autonomous open-die forging

Roy Rechenberg¹ , Grzegorz Korpala¹, Magdalena Jabłońska², Marek Wojtaszek³, Krystian Zyguła³, Marek Tkocz⁴, Iwona Bednarczyk⁴, Karolina Kowalczyk⁵, Ulrich Prahl¹

¹TU Bergakademie Freiberg, Akademiestraße 6, 09599 Freiberg, Germany.

²Lukasiewicz Research Network – Institute of Non-Ferrous Metals, ul. Sowińskiego 5, 44-100 Gliwice, Poland.

³AGH University of Krakow, al. Adama Mickiewicza 30, 30-059 Kraków, Poland.

⁴Silesian University of Technology, ul. Akademicka 2A, 44-100 Gliwice, Poland.

⁵University of Silesia, ul. Bankowa 12, 40-007 Katowice, Poland.

DOI:

https://doi.org/10.7494/cmms.2025.2.1018

Abstract:

Open-die forging is a key process for manufacturing large components such as generator shafts and crankshafts for ship engines. Despite its industrial relevance, the process remains dependent on manual labour and operator expertise, leading to challenges in process stability, reproducibility, and efficiency. Traditional automation approaches are impractical due to the high variability and low production volumes typical of open-die forging. At the Institute of Metal Forming (IMF) at the TU Bergakademie Freiberg, a novel concept for autonomous open-die forging has been developed and tested. The system combines conventional forging equipment with advanced technologies, including industrial robotics, 3D laser scanning, thermal imaging, and modular control software. Central to the concept is a robot cell operating as a distributed system, where sensor data is used to create a digital twin of the workpiece. This enables adaptive process planning and real-time autonomous operative adjustments. A process planning tool generates pass sequences and commands for manipulator movements, while an electromechanical interface allows indirect control of the forging press. The modular software architecture, coordinated by a central core-module, ensures flexibility and facilitates integration into different production environments. Initial trials demonstrate the system’s potential to improve process stability and quality while reducing dependency on manual operation. Ongoing work focuses on refining the concept to meet industrial requirements and support advanced material applications.

Cite as:

Rechenberg, R., Korpala, G., Jabłońska, M., Wojtaszek, M., Zyguła, K., Tkocz, M., Bednarczyk, I., Kowalczyk, K., & Prahl, U. (2025). Design and implementation of a digital infrastructure for autonomous open-die forging. Computer Methods in Materials Science, 25(2), 5-15. https://doi.org/10.7494/cmms.2025.2.1018

Article (PDF):

Keywords:

Automation, Forging, Open-die forging

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