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

Öz

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.

Anahtar Kelimeler

Kaynakça

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Ayrıntılar

Birincil Dil

İngilizce

Konular

Sayısal Modelleme ve Mekanik Karakterizasyon

Bölüm

Araştırma Makalesi

Yazarlar

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

Ömer Eyercioğlu
0000-0002-9076-0972
Türkiye

Yayımlanma Tarihi

27 Mayıs 2026

Gönderilme Tarihi

3 Mart 2026

Kabul Tarihi

30 Mart 2026

Yayımlandığı Sayı

Yıl 2026 Cilt: 3 Sayı: 1

DOI

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

IZ

https://izlik.org/JA59RJ84RM

Kaynak Göster

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, ve 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 (01 Mayıs 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 ve Ö. Eyercioğlu, “Development of an Offline Digital Twin Framework for Forging Dies Based on the Upper Bound Energy Method”, NASE, c. 3, sy 1, ss. 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 (01 Mayıs 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, ve Ömer Eyercioğlu. “Development of an Offline Digital Twin Framework for Forging Dies Based on the Upper Bound Energy Method”. Natural Sciences and Engineering Bulletin, c. 3, sy 1, Mayıs 2026, ss. 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. 01 Mayıs 2026;3(1):69-78. doi:10.66754/nase.1901556