Image Analysis Applied to Monitoring the Hot Open Die Forging Process with Drop Hammer

In gravity drop hammer forging, the ram is lifted to a certain height and then released. During the downward motion, the hammer is accelerated by gravity and strikes the workpiece. The operational environment of these machines presents adverse conditions, such as extreme temperatures, high impact velocity, and intense energy generation. These aspects make the instrumentation of these machines highly challenging, leading to the use of theoretical models to describe their dynamic behavior. However, these models involve simplifications that reduce the accuracy of the analyses. This study aims to evaluate the efficiency of Digital Image Correlation (DIC) as a monitoring tool for the hot forging process of AA 6351 aluminum alloy using a drop hammer. Digital Image Correlation allows for the quantitative analysis of the evolution of the workpiece deformation during the process, providing valuable data on process and machine performance. The results obtained demonstrate that Digital Image Correlation is a promising approach for monitoring the hot forging process with a drop hammer, with the potential to enhance the quality of the final product and process efficiency.