The main subject of the present work is investigation of possibility of extension of classical orbital forging technology to obtain more cost effective forging process. Orbital forging is the process used for forging of shaped parts by applying the incremental forging method. Results of simulation of orbital forging are compared in the present work with the result obtained from a conventional forging process. 3D finite element (FE) simulations are used in the present project to evaluate the capabilities of the orbital forging process and proper die design, and to predict the forging loads the. Selected results of simulations are presented in the paper. These results are the basis for the further comparison and discussion about possible modifications of conventional orbital forging approach.
The development of a numerical model capable of simulating the forming processes characterized by additional reversible movement of tools is the subject of this paper. The major assumption of this process is the introduction of additional shear stresses into the material in order to induce the strain path change effect. The scope of the problem is very broad, so the focus in the present work is on the process of flat rolling with additional oscillatory movement of rolls along their axes. Due to the sophisticated nature of this process particular attention is paid to the reduction in computational time by minimizing the number of required finite elements. The developed model is used to study differences in material behaviour during rolling with different roll velocities. A detailed description of the developed numerical model and examples of obtained results are presented in this paper. A comparison with experimental analysis is presented, as well.
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