Analysis of the hot radial forging process according to the finite element method
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ORIGINAL ARTICLE
Analysis of the hot radial forging process according to the finite element method Saeed Darki 1 & Evgeniy Yurevich Raskatov 1 Received: 4 February 2020 / Accepted: 30 July 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract The radial forging process (RFP) is an advanced technology that many scientists have recently been trying to optimize and improve in order to enhance the quality of products and save energy in manufacturing. However, controlling the process when employed on large products is very difficult due to the appearance of cracks. During RFP, a tube is repeatedly and continuously exposed to stroking and feeding. Thus, when the die comes into contact with the product, the rotational feed stops. Afterwards, when the hummers break contact with the tube, the axial and rotational feeds are applied simultaneously in order to obtain a good surface finish at a specific rotation angle feed. Implementing RFP is a costly and lengthy process largely done through trial and error. It depends on variables such as material temperature, rotation speed, rate of feed, parameters of die geometry, die pressure, and amplitude. Thus, a symmetric 3D model simulation has been conducted with commercial FEM software. The results include the cantors of residual stress (RS), strain velocity, and temperature. Equally, the contact forces have been measured as experimental results, and there is a good correspondence between the two types of results. Keywords Three-dimensional finite element method . Tube diameter reduction . Radial forging . Residual stress
1 Introduction Hot radial forging is a particular form of the open forging process. Based on this process, a tube or hollow shaft is deformed across four dies and one mandrel, which increases the stiffness of the product and changes its radius. Open forging is mainly used to reduce the dimeter of ingots made from special alloys. Consequently, radial die forging is a costly and complex process. Recently, many scientists have studied RFP to obtain benefits such as decreased process costs, material Highlights • A RFP simulation has been carried out with 3D FEM software. • In terms of material analysis, the viscoplastic model has been assumed. • The ranges of RS, total strain, and total force have been calculated. • The results can be implemented in the forging operations to refine the final characteristics of the workpiece. * Saeed Darki [email protected] Evgeniy Yurevich Raskatov [email protected] 1
New Material and Technology Institute, Ural Federal University, Ekaterinburg, Russia
savings, increased product quality and quantity, and improved process parameters. Before the current study, other scientists studied RFP in terms of rigid plastic formulation in order to investigate RS. Ameli and Movahhedy [1] developed a cold type of RFP through axisymmetric and 3D-FEM modelling in order to provide the stress rate and die pressure on a tube with grooves. They state that an axisymmetric simulation matches the experimental results; however,
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