Computer Aided Metal Flow Simulation and Die Design Optimization for Axisymmetric Forging Process

Summary

A CAD system has been developed for closed die forging and optimization. This system includes rules for geometrical design of the die and a finite element package for metal flow simulation, based on the rigid plastic formulation. Using this system the initial shape of the die is predicted based on empirical guidelines. Then simulation of metal flow is carried out to check wether the material flow is taking place without any defect and to insure the completion of the die filling. Using the field variable of the metal flow-simulation at the final stage of deformation, the actual die is analyzed using an elastic-plastic finite element package resident in the same computer to see wether there is any likehood of die failure due to over stressing. If appropriate, the die is modified to prevent premature failure.

This paper presents an example of axisymmetric closed die forging illustrating all the design steps including die failure due to insufficient dimensions of the initial die size. Both experimental and theoretical design procedure is presented.