Finite Element Simulation on Die Forging Process for Case Forging
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Based on the thermal-mechanical coupling model,the numerical simulation of die forging process for 7075 Al-alloy case forging was performed by rigid-plasticity finite element software DEFORM-3D.The influences of the starting forging temperature and deformation velocity in case forging forming process were investigated.The optimizing forging process parameters are starting forging temperature 450 ℃ and deformation velocity 2 mm /s.Cite
The model of the final forging blade was established by three-dimensional modeling software Pro/E.The process of the final forging blade was simulated with finite element software DEFORM-3D.The effects of different beginning forging temperature,friction factor and the upper die pressing speed on the final forging process of the blade were analyzed.The evolution rule of temperature field of final forging blade under different process parameters was researched.
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The filling capability of forging die is the key to design forging die and it exerts an important influence to the quality and life of die. In response to the difficulty in filling of forging die,and taking 2A12 aluminum alloy as the research object,the bar filling height after forging as the control objective,the finite element numerical simulation method was used to simulate the forging process. This test simulated the process of die forging,analysed the deforming behavior of the stuff and discussed the variety and distribution of temperature and strain。
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As the most important components of marine power installation,the quality of the long-axis heavy forgings has a direct influence on the hydrodynamic characteristics and normal voyage of marine.The squaring process of the marine intermediate shaft forged by flat anvil,FM method and the unequal flat anvil was simulated.The finite element model was established based on numerical simulation software Deform-3D,and the temperature field,stress distribution,forging force and forging efficiency were analyzed.The results show that comparing with the FM method and unequal flat anvil forging,when forging by flat anvil,the forming efficiency is the highest,the forging force is the smallest and the deceasing speed of the surface temperature of forging billet is the slowest;when forging by FM method,the ideal compressive stress distribution state can be obtained along the billet cross section.
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Using Forge 2D/3D forging finite element simulation software,the forging environment and deformation process of large forging case were simulated and analyzed.The influences of forging temperature,die design,forging equipment and other factors on the forging blank were discussed.The stress and strain,rule of metal flowing,forging flaw,metal lines,the final geometrical shape of finished forging,etc.during forging were analyzed.The important parameters,such as the weight of cropping,forging energy,heating times,die design,etc.in forging technology design were determined,which provide a reference for forging technology design in actual production.
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The numerical thermal mechanical simulation of radial forging process of C45 steel stepped shaft with GFM forging machine was carried out by three dimensional finite element method DEFORM 3D. According to effective plastic strain, mean stress and mean plastic strain distribution of the radial forging process, the forging penetration efficiency (FPE) was studied throughout. The results show that: effective plastic strain in the center of the forging is never be zero; The mean stress in the center of the workpiece is proposed to describe hydrostatic pressure in this paper. There is compressive strain layer beneath the surface of the workpiece, while there is tensile strain layer in the center of the forging. These studied results could be a valuable reference for designing the similar forging operations.
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In the open die forging,the type of flash has great influence on the process of forging.The process of forging a same part with different type of flash was simulated by DEFORM, a large simulation software,using a finite element method.By comparing the simulation results,the conclusion how diferent type of flash will influence the filling of the mold and the forging force is achieved.
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Isothermal process
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Based on thermal-coupled model,numerical simulation of die forging process of 7075 Al-alloy fire base was performed by rigid-plasticity finite element software.The influence of main technique parameters in the forming process was discussed and the appropriate before forging temperature of 420℃and deformation speed of 20 mm/s was determined.
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