Numerical Model Simulation of the Double-Roll Rotary Forging of Large Diameter Thin-Walled Disk

Abstract

Double-roll rotary forging is an emerging plastic forming technology based on rotary forging. Owing to the advantages of being labor-saving, a small eccentric load, low noise and vibration, good uniformity, high surface quality, and material saving, it is very promising for the fabrication of large diameter thin-walled disks. To date, little relevant research on the double-roll rotary forging technology of large diameter thin-walled metal disks has been reported, and the deformation characteristic and the influence of three key parameters on the double-roll rotary forging process remain uninvestigated. Herein, a reasonable 3D rigid-plastic numerical model of the double-roll rotary forging of a disk workpiece is established under the Deform software environment. Based on the valid 3D numerical model, the deformation mechanism, and the effective laws of three key parameters (feed rate v of the lower die, rotational speed n of the upper die, and the initial temperature T of the disk workpiece) on the metal flow and force and power parameters in the double-roll rotary forging process have been explored. The research results provide valuable guidelines for a better understanding of double-roll rotary forging for the fabrication of large diameter thin-walled disks.

Analysis and Improvement of an Industrial Process of Hot Die Forging of an Elongated Forging Tipped with a Joggle with the Use of Numerical Simulation Results

“…This is especially justified in the case when the forging has a complex shape such as that of a turbine blade, a toothed gear, a yoke, etc. [17][18][19][20][21][22][23][24][25][26]. In turn, the authors of [17] developed an experimental-numerical methodology of identifying coefficients for constitutive equations in the case of die forging on presses.…”

“…The article [25] demonstrates the results of a numerical simulation by means of Deform 2D/3D of a flange forging in a multi-operation forging process, in which 42CrMo4 steel pipes were used as the ingot material. In turn, the authors of the article [26] apply numerical simulations of the process of forging railroad axles from steel with the use of the Forge program, with the consideration of the grain size evolution in a multi-operation forging process with high deformation rates.…”