New schemes of forging plates, shafts, and discs

This paper presents the various ways of forging large forged pieces such as shafts, plates, and discs. A finite element method was used to simulate open die forging processes such as forging by flat dies with a slant, forging by staged dies, and upsetting of profiled workpiece. The parameters of the stress strain state of the billet in these processes were determined, along with the rational parameters for forging plates by flat dies with slant such as tool size and mechanical modes. The optimal die step dimension and mechanical regime for forging shafts by staged tools was determined. Also, the rational geometric parameters of the workpiece for forging discs by upsetting were determined. For these forging schemes, a simulation was done of the microstructure evolution in forgings obtained by traditional technology and new proposed technology. The paper shows the advantages of new forging schemes which provide a uniform distribution of grain size in the obtained billets.