Development of an Analysis Method for Radial Forging Parameters Based on Hardness Criterion

Abstract

Considering the complexity of the radial forging process, the study of dynamic and thermodynamic parameters is of great importance. With the severe deformation of a workpiece in a plastic state, the effects of all parameters affecting the final geometry of the forging pipe need to be optimized. Thus, the mathematical model of the process is based on visco-plastic material, taking into account thermomechanical coupling and the surface properties during forging, including the hardness of the workpiece and friction. The results present the effects of a die angle on residual stress, total wear, and contact force, leading to ideal operating conditions and the ideal design of machine parts. In order to ensure the accuracy of the calculations and predictions made through software, a hardness test was performed experimentally, which showed the hardness curve of the microstructure and the strain of the workpiece. This indicates the consistency and accuracy of the results obtained from both methods. In order to improve the process and the tube employed, using an optimized die is recommended.

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

“…Makiyama [19] conducted a finite element simulation using commercial software FORGE to study the effect of rotational feed emulating four-die radial forging on the forged shape in mandrel-less incremental forging of thick circular tube. Darki and Raskatov [20] developed a 3D visco-elastoplastic finite element model to predict the effect of the die angle on the forging load and the residual stresses in the workpiece. Mackey et al [21] used a finite element model of the radial forging process with cohesive zones to simulate the evolution of non-metallic inclusions during the forging process.…”

“…and(20), respectively, for different values of rotational feed angle. According to these figures, the most uniform and the most compressive stress distributions are obtained in…”