In the normal electrical upsetting process, the process parameters were determined by experience. During working, these parameters were constant and could not be controlled on line. In this paper a new computer-controlled electrical upsetting system is introduced. Based on analysis of main process parameters such as upsetting velocities, heating current and upsetting pressures, the optimum control system of process parameters is determined. The control strategy includes two key parts: sensing the temperature from the system pressure and controlling temperature by adjusting the current i or velocity V1 and keeping V2 = [d2/(2h2 + d2)]V1 to realize spherical upsetting.
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