The Need

Incremental forging offers manufacturers a flexible route to produce near-net-shape components without dedicated dies, but process planning remains highly dependent on operator expertise, trial-and-error development, and time-consuming programming. As part geometries become more complex, determining the optimal sequence of forging actions to achieve dimensional targets while maintaining productivity becomes increasingly difficult. Industry needs automated process planning solutions that can reduce setup time, improve repeatability, and enable robotic forging systems to manufacture complex parts with minimal human intervention.

The Technology

OSU engineers have developed an intelligent control and path-planning framework for robotic incremental forging systems. The software automatically generates and executes a sequence of forging actions that progressively transform stock material into a desired target geometry. Using real-time metrology feedback from onboard sensors, the system continuously updates its understanding of the part state and adjusts decisions accordingly. The approach can also evaluate multi-step forging trajectories in a virtual environment before execution, allowing the robot to efficiently converge on the desired shape while reducing reliance on manual process planning.

Commercial Applications

• Advanced robotic forging platforms and digital manufacturing systems seeking autonomous process planning capabilities.
• Automated production of rotationally symmetric shafts, rods, and stepped components.
• Aerospace, defense, and energy-sector forging of low-volume, high-value metal parts.

Benefits/Advantages

• Reduces manual programming requirements
• Improves manufacturing efficiency
• Supports closed-loop operation
• Hardware-agnostic architecture