Application of Physical Similarity Utilizing Soft Modeling Materials and Numerical Simulations to Analyse the Plastic Flow of UC1 Steel and the Evolution of Forces in a Specific Multi-Operational Industrial Precision Forging Process with a Constant-Velocity Joint Housing

This article concerns an application of physical similarity using soft non-metallic materials to compare and identify plastic flow and evolution of forces during a multi-operational precision forging of UC1 steel with a constant-velocity joint housing. Studies were conducted in order to analyze and select the optimal profile of the working impression of the bottom tool used in the second forging operation with the application of two die shapes (arched and conical) as well as the preforms corresponding to them, in the form of cylinders of slightly different geometry but of the same volume. In the first stage of studies, the modeling material was selected on the basis of “Filia” synthetic wax with modifiers, and the group of materials best fitting the actual material, UC1 steel, were selected for tests according to the author’s original condition of plastic similarity. Next, extrusion forging experiments were conducted with both die shapes applied in the industrial process (appropriately adapted) on a specially designed physical modeling station – a horizontal press. Conducted tests demonstrated that a more uniform method of material flow and lower forces on the punch were achieved with the arched profile than with conical dies. The results obtained were additionally confirmed by numerical simulation of the industrial forging process, which also demonstrated that the application of arched dies is more favorable due to strain distribution and forces.