Investigation of the influence of various process parameters on the radial forging processes by the finite element method (FEM)

Abstract

In this study, the finite deformation theory was used to develop a large rigid-plastic deformation finite element program which could simulate the radial forging process of work-hardening materials. First, experiments were carried out to confirm the accuracy of the program. Then we investigated the influence of each parameter on the forging process. The parameters adopted in this study are die corner radius (R), ring gap height (H), friction factor (m), and work-hardening coefficient (n). The effects of parameters on the flange thickness ratio (h/H) and the outer protruding shape ratio (D/D 0 ) are also obtained.The relationship between the process parameters and the deformation behaviours under radial forging is obtained through simulation. When the radius of die corner and the ring gap height are larger, the flange thickness ratio (h/H) becomes larger, but the outer protruding shape ratio (D/D 0 ) decreases. The value of friction factor (m) doesn't seem to affect the flange thickness ratio (h/H) much, but the outer protruding shape ratio (D/D 0 ) decreases upon increasing the friction factor. When the work-hardening coefficient (n) is larger, the flange thickness ratio (h/H) is also larger, but the outer protruding shape ratio (D/D 0 ) decreases.The results of this study offer some advanced knowledge about finding the best designs of process and die in radial forging process.

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