Development of an Offline Digital Twin Framework for Forging Dies Based on the Upper Bound Energy Method

Adem Aksoy; Ömer Eyercioğlu

doi:10.66754/nase.1901556

Development of an Offline Digital Twin Framework for Forging Dies Based on the Upper Bound Energy Method

Abstract

The reliable prediction of forging load during the early stages of die design is critical for ensuring process feasibility, die durability, and press capacity selection, particularly in the forging of geometrically complex components such as gears. Conventional trial-and-error procedures and finite element simulations, although effective, may significantly increase development time and computational cost. In this study, an analytically driven offline digital twin framework is developed for gear forging die design by integrating an Upper Bound Energy Method-based analytical formulation with a structured parameter space architecture. The proposed framework enables rapid estimation of forging load as a function of key geometric, material, and process parameters without relying on real-time sensor data or computationally intensive simulations. A systematic dataset is generated through controlled variation of billet dimensions, gear geometry, friction conditions, and forming parameters within industrially relevant ranges. The predictive capability of the analytical core is validated using experimentally reported benchmark forging cases under fully filled die conditions. The results demonstrate that the proposed model preserves the overall trend of experimental measurements while providing conservative load estimates within acceptable engineering tolerance limits. The developed offline digital twin framework functions as a computationally efficient decision-support tool for early-stage die design and contributes to the integration of analytical modelling and digitalization strategies in metal forming engineering.

Keywords

References

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Details

Primary Language

English

Subjects

Numerical Modelling and Mechanical Characterisation

Journal Section

Research Article

Authors

Adem Aksoy ^*
0000-0002-3188-2697
Türkiye

Ömer Eyercioğlu
0000-0002-9076-0972
Türkiye

Publication Date

May 27, 2026

Submission Date

March 3, 2026

Acceptance Date

March 30, 2026

Published in Issue

Year 2026 Volume: 3 Number: 1

DOI

https://doi.org/10.66754/nase.1901556

IZ

https://izlik.org/JA59RJ84RM

Cite

RIS / Bibtex

APA

Aksoy, A., & Eyercioğlu, Ö. (2026). Development of an Offline Digital Twin Framework for Forging Dies Based on the Upper Bound Energy Method. Natural Sciences and Engineering Bulletin, 3(1), 69-78. https://doi.org/10.66754/nase.1901556

AMA

1.Aksoy A, Eyercioğlu Ö. Development of an Offline Digital Twin Framework for Forging Dies Based on the Upper Bound Energy Method. NASE. 2026;3(1):69-78. doi:10.66754/nase.1901556

Chicago

Aksoy, Adem, and Ömer Eyercioğlu. 2026. “Development of an Offline Digital Twin Framework for Forging Dies Based on the Upper Bound Energy Method”. Natural Sciences and Engineering Bulletin 3 (1): 69-78. https://doi.org/10.66754/nase.1901556.

EndNote

Aksoy A, Eyercioğlu Ö (May 1, 2026) Development of an Offline Digital Twin Framework for Forging Dies Based on the Upper Bound Energy Method. Natural Sciences and Engineering Bulletin 3 1 69–78.

IEEE

[1]A. Aksoy and Ö. Eyercioğlu, “Development of an Offline Digital Twin Framework for Forging Dies Based on the Upper Bound Energy Method”, NASE, vol. 3, no. 1, pp. 69–78, May 2026, doi: 10.66754/nase.1901556.

ISNAD

Aksoy, Adem - Eyercioğlu, Ömer. “Development of an Offline Digital Twin Framework for Forging Dies Based on the Upper Bound Energy Method”. Natural Sciences and Engineering Bulletin 3/1 (May 1, 2026): 69-78. https://doi.org/10.66754/nase.1901556.

JAMA

1.Aksoy A, Eyercioğlu Ö. Development of an Offline Digital Twin Framework for Forging Dies Based on the Upper Bound Energy Method. NASE. 2026;3:69–78.

MLA

Aksoy, Adem, and Ömer Eyercioğlu. “Development of an Offline Digital Twin Framework for Forging Dies Based on the Upper Bound Energy Method”. Natural Sciences and Engineering Bulletin, vol. 3, no. 1, May 2026, pp. 69-78, doi:10.66754/nase.1901556.

Vancouver

1.Adem Aksoy, Ömer Eyercioğlu. Development of an Offline Digital Twin Framework for Forging Dies Based on the Upper Bound Energy Method. NASE. 2026 May 1;3(1):69-78. doi:10.66754/nase.1901556