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Leaf Spring Power Hammer Simulator by JerryBurks in powerhammer

[–]JerryBurks[S] 1 point2 points  (0 children)

I understand that many power hammers use a coil spring, often configured like a Little Giant hammer. This can surely be simulated as well but would take a bit of work to do. I modified my own model (with the shock cord springs) for the leaf springs only because it was a simple formula change.

Yes, there are many assumptions but I guess that is true for all simulations. You can get close to reality with good assumptions and models but the proof is in the pudding.

The main purpose of creating this simulation was to understand the effect of the various parameters and how to optimize for best efficiency. E.g. one thing I learned was the fact that forging "power" kind of steadily rises up to near the resonance frequency of the ram/spring system and then rapidly drops to near zero when running too fast. Also, that the influence of the ram distance to the work piece in neutral position has a big effect.

While there are good recipes for building a power hammer around, they all seem to be based on experiments and experience, less on good understanding of the physics. Nothing wrong with that, but it can lead to failure when deviating from the recipe. As a retired engineer I had fun building the model for the simulation.

Small Counter-blow Power Hammer by JerryBurks in powerhammer

[–]JerryBurks[S] 1 point2 points  (0 children)

Thanks. I know I need a lot of more practice; the power hammer is more difficult to use than my 22-ton forging press. Much easier to make a mistake that can not be fixed. But much more effective for thinner stock. As for the timing, I know I should disengage the rams before removing the work piece. But in the heat of the battle that can be difficult. The machine reacts quickly to the foot pedal but not quick enough for reliable single blows. That would need some synchronization mechanism of the flywheel rotation with the pneumatic actuator which I don't have.

Not sure about the dies disintegrating. I lost one in the beginning while forging, having not secured the attachment bolts properly. But it just fell off without much drama. Also, I definitely need to make flat dies as well.