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A dynamic model for simulation of hot radial forging process

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Huang, Jianglin, Slater, Carl, Mandal, Anup and Blackwell, Paul (2017) A dynamic model for simulation of hot radial forging process. Procedia Engineering, 207 . pp. 478-483. doi:10.1016/j.proeng.2017.10.808

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Official URL: https://doi.org/10.1016/j.proeng.2017.10.808

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Abstract

A comprehensive dynamic process model has been developed to investigate features of the inherently transient hot radial forging process, taking account of complex process kinematics, thermo-elastoplastic material behaviour and microstructural evolution. As an input to this model, a fully systematic thermomechanical testing matrix was carried out on a Gleeble 3800 including temperature (20-1100°C), strain (up to a true strain of 1) and strain rates (from 0.1 to \textgreater50 s-1). The proposed model can accurately capture vibration characteristics due to the high frequency short strokes during radial forging, which have been found to have a strong effect on material flow, forging load. Numerical analyses were performed to investigate the effect of different axial spring stiffnesses on forging load, strain distribution in the workpiece, and maximum axial feeding rate. It has been found that forging load increases significantly with increasing stiffness of the axial spring. The axial spring stiffness was also found to have a strong effect on determination of axial feeding rate and reduction ratio of workpiece by limiting the axial vibration amplitude of workpiece under the maximum compression of spring coil to avoid hard stop of workpiece in the axial direction during forging. It has been found that the spring stiffness does not have a strong effect on the strain distribution in the work piece. For practical application, the proposed model is applied to simulate the manufacturing process of a hollow transmission shaft using a GFM SKK10/R machine. Simulation results based on a 3 dimensional framework provide a detailed insight of material flow, residual stress and grain size evolution during the multiple pass radial forging process and the results are compared with available experimental measurements. The results provide valuable insights for process design.

Item Type: Journal Article
Subjects: T Technology > TN Mining engineering. Metallurgy
T Technology > TS Manufactures
Divisions: Faculty of Science > WMG (Formerly the Warwick Manufacturing Group)
Library of Congress Subject Headings (LCSH): Steel -- Thermomechanical properties -- Testing, Steel forgings
Journal or Publication Title: Procedia Engineering
Publisher: Elsevier
ISSN: 1877-7058
Official Date: 15 November 2017
Dates:
DateEvent
15 November 2017Available
17 September 2017Accepted
Date of first compliant deposit: 29 May 2019
Volume: 207
Page Range: pp. 478-483
DOI: 10.1016/j.proeng.2017.10.808
Status: Peer Reviewed
Publication Status: Published
Access rights to Published version: Open Access
RIOXX Funder/Project Grant:
Project/Grant IDRIOXX Funder NameFunder ID
UNSPECIFIEDInnovate UKhttp://dx.doi.org/10.13039/501100006041
113061Jaguar Land Rover (Firm)http://viaf.org/viaf/305209406

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