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Void closure during open die forging of large size martensitic stainless-steel ingots: an experimental-analytical-numerical study

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Abstract

In the present research, void closure during the open die forging process of large size AISI410 martensitic stainless-steel ingots was studied using a combination of analytical modeling, finite element simulations, and experimental validations. The analytical model assumes that the voids during deformation can be represented by initially spherical geometry changing to ellipsoid or cracks before being completely closed. Finite element simulations of the open die forging were conducted using the Forge® NxT 3.1 software to simulate the stresses and strains predicted by the analytical model. Hot forging experiments were conducted on large size cylindrical samples at the center of which spherical voids simulating the presence of porosity, were machined. After hot forging, the closure levels of the voids were compared with those predicted by the model and very good agreement (discrepancy in the range of 7%) was observed. This showed that the model could be confidently used for prediction of the void closure in industrial open die forging processes.

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Abbreviations

\({E}_{e}\) :

Effective strain

\({H}_{i}\) :

Industrial ingot height

\({H}_{e}\) :

Experimental sample height

\(m\) :

Strain rate sensibility coefficient

\(n\) :

Norton coefficient

\({q}_{1};{q}_{2};{q}_{3};{q}_{4}\) :

Constants in the model by Zhang et al. [35] for voids closure

\({S}_{f}\) :

Final void cross sectional area

\({S}_{i}\) :

Initial void cross sectional area

\({T}_{x}\) :

Stress triaxiality (the hydrostatic stress divided by the Von Mises stress)

\({V}_{f}\) :

Final void volume

\({V}_{i}\) :

Initial void volume

\({\dot{\varepsilon }}_{i}\) :

Strain rate

\({\sigma }_{i}\) :

Stress

\({\Phi }_{i}\) :

Industrial ingot diameter

\({\Phi }_{e}\) :

Experimental sample diameter

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Acknowledgements

The authors would like to thank Finkl Steel-Sorel for funding this research study and supplying materials through Mitacs Grant No. IT16470.

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Authors and Affiliations

  1. Department of Mechanical Engineering, École de Technologie Supérieure, Montreal, QC, Canada

    Antoine Geisler, Morteza Sadeghifar & Mohammad Jahazi

  2. Finkl Steel- Sorel, 100 McCarthy, St-Joseph-de-Sorel, QC, Canada

    Jean-Benoit Morin & Abdelhalim Loucif

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  1. Antoine Geisler
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Correspondence to Morteza Sadeghifar.

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Geisler, A., Sadeghifar, M., Morin, JB. et al. Void closure during open die forging of large size martensitic stainless-steel ingots: an experimental-analytical-numerical study. Int J Mater Form 16, 11 (2023). https://doi.org/10.1007/s12289-022-01735-y

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