A virtual plant, built in a computer by using computer graphic (CG) and Virtual Reality (VR), can model the precise and whole structure of an integrated manufacturing system and simulate its physical and logical behavior in operation. This paper aims to reveal the advanced modeling and VR realization methods in developing a virtual forging plant for automatic and programmed open-die forging processes. Two sub-models, component model and process model, compose the overall modeling architecture of a virtual integrated open-die forging plant. The coordinated motion simulation of the integrated system is realized through a kinematic modeling method. A compound stiffness modeling method is then developed to simulate the mechanical behavior in operation. The process simulation of the virtual plant is conducted on the basis of the above two modeling methods. A practical application example of virtual plant for integrated open-die forging process is presented towards the end.
