Abstract
In order to reduce the casting defects in the large forgings such as solidification segregation, a new forming technology of the semi-solid liquid core forging is put forward in this paper. We elucidate the effectiveness of the semi-solid liquid core forging by simulating the forging process of the 19 tons flat steel ingot in the commercial software DEFORM-3D. A coupled temperature/stress finite element (FE) model is developed to calculate the temperature, the effective stress, the effective strain, the maximum principal stress and the anvil force. These output variables are compared correspondingly from the semi-solid liquid core forging and the traditional forging after the first pass reduction. The deformation of the semi-solid liquid core forging is more uniform and the equipment capacity is also improved. Compared with the traditional forging, the new forging technology is directly forged at high temperature without reheating for a long time and the energy is saved.
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