A Study on the Effect of the Die Transverse Angle and the Part Rotational Feed Angle in the Cold Radial Forging Process of Rods

Abstract

Radial forging is an efficient and high-precision process for manufacturing rotary parts such as shafts, axles, and gun barrels. While this process has been extensively investigated in the literature, effect of some parameters like the die transverse angle and the part rotational feed angle has not been adequately studied since simulating several steps of this process with a full three-dimensional model is required for this purpose which is laborintensive and time-consuming. To bridge this gap, in this paper a three-dimensional nonlinear finite element model has been developed to analyze effects of the die transverse angle and part rotational feed angle in this process. To address the lack of reliable experimental data in the literature, an innovative approach has been proposed and used for validation of the developed finite element model. It has been observed that dies with transverse angle of 155ᵒ and 165ᵒ provide the best performance in producing a part geometry close to the desired shape. However, the most uniform residual stress distribution is obtained in forging by a die with a smaller transverse angle. Furthermore, for improving the shape and quality of the final product, the part rotational feed angle should be reduced as much as possible.