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Modeling of Closed-Die Forging for Estimating Forging Load

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Abstract

Closed die forging is one common metal forming process used for making a range of products. Enough load is to exert on the billet for deforming the material. This forging load is dependent on work material property and frictional characteristics of the work material with the punch and die. Several researchers worked on estimation of forging load for specific products under different process variables. Experimental data on deformation resistance and friction were used to calculate the load. In this work, theoretical estimation of forging load is made to compare this value with that obtained through LS-DYNA model facilitating the finite element analysis. Theoretical work uses slab method to assess forging load for an axi-symmetric upsetting job made of lead. Theoretical forging load estimate shows slightly higher value than the experimental one; however, simulation shows quite close matching with experimental forging load, indicating possibility of wide use of this simulation software.

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Abbreviations

α s :

Angle of inclination, or half the taper angle

β :

Shear angle

Δh :

Infinitesimal small steps of stoke

Δv 23 :

Volume of metal displaced inward in zones 2 and 3 as the die advances

Δv 4 :

Volume of metal flowing towards shaft

Δv f :

Volume of additional upset in flange cavity

σ 1 :

Flow stress inside zone 1

σ 2 :

Flow stress inside zone 2

σ 3 :

Flow stress inside deformation zone

σ 6 :

Flow stress inside zone 6

σ i :

Flow stresses

σ n :

Axial stress at neutral surface

σ Z1 :

Axial stresses at zone 1

σ Z2 :

Axial stresses at zone 2

σ z3 :

Axial stress

σ z3ave :

Averaged axial stress at the boundary of zones 2 and 3

σ z4 :

Axial stress distribution in the shaft due to converging flow

σ z5(r=RF) :

Axial stress at r = RF calculated from zone 5

σ zb :

Axial stress at the top surface of deformation zone

ds :

Diameter of deformation zone

f 1 :

Friction factor at die and zone 1 interface

f 2 :

Friction factor at dies and zone 2 interface

f f :

Friction factor at the flange

f 4 :

Friction factor at the interface of dies and zone 4

h s :

Thickness at a point, s

P 1 :

Axial load to upset zone 1

P 2 :

Forging load to upset zone 2

P s :

Forging load to extrude the shaft

P t :

Total forging load

P tu :

Total forging load at the upsetting stage

r s :

Radius at a point, s

R n :

Radius of neutral surface

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Acknowledgments

The present paper is an extended version of the paper titled ‘Exploring Forging Load in Closed-Die Forging’ presented in 5th International and 26th All India Manufacturing Technology, Design and Research (AIMTDR) Conference held at Indian Institute of Technology Guwahati, India during December 12–14, 2014.

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Authors and Affiliations

  1. Bharat Heavy Electricals Limited (BHEL), BHEL Site Office, Bellary TPP, Kudathini, Karnataka, 583115, India

    Debashish Sheth

  2. Kalyani Government Engineering College, Kalyani, West Bengal, 741235, India

    Santanu Das

  3. CSIR-Central Mechanical Engineering Research Institute, Durgapur, West Bengal, 713209, India

    Avik Chatterjee

  4. Indian Institute of Technology Patna, Bihta Campus, Bihta, Bihar, 801103, India

    Anirban Bhattacharya

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  1. Debashish Sheth
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Correspondence to Santanu Das.

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Sheth, D., Das, S., Chatterjee, A. et al. Modeling of Closed-Die Forging for Estimating Forging Load. J. Inst. Eng. India Ser. C 98, 53–61 (2017). https://doi.org/10.1007/s40032-016-0236-y

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  • DOI: https://doi.org/10.1007/s40032-016-0236-y

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