The paper presents selected examples of solutions and specific user applications associated with the industrial forging processes. Various process specific issues encountered during many years of bilateral collaboration with the forging industry are addressed and analysis methods are presented. As demonstrated in numerous articles and publications, the parameters influencing the die forging process are subject to complicated and mutually related dependencies, which can affect and complicate the methods of analysis. For this reason, researchers, more and more frequently, involve the use of additional support tools such as CAD / CAM / CAE, numerical modelling based on FEM, tool surface scanning methods, physical modelling, advanced microstructural research and dedicated control-measurement systems to validate engaged solutions. The research conducted by the authors included mainly: an analysis of the preform preparation, the impact of the geometry on the forging quality and the heating methods of the material and the tools, analysis of the tribological conditions, as well as an optimization of selected processes in respect of the force parameters, strain and temperature distributions and finally, a weight minimization of the input material. The issues discussed by the authors in the article intend, on the basis of the experience of its creators, to review the issues of the current forging technology and to indicate its possible solutions and development directions.
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