Abstract
The present paper deals with the three dimensional finite element simulation of rotary sinter-forging of cylindrical preforms using DEFORM-3D software. Aluminum sintered preforms were fabricated by the powder metallurgy route and basic experiments concerning simple compression tests were performed. The corresponding flow curve (stress-strain) data was added to the material library of the software. Further, the aluminum preforms were subjected to rotary forging operations and change in the preform relative density and diameter (preform top surface) with preform height reduction were recorded, plotted and analyzed. The distribution of total displacement, effective stress, effective strain and velocity plot in form of color codes and contours on the preform surface were obtained and critically analyzed. Also, the data for variation of radial displacement (preform top surface), die-preform interfacial contact area, average forging load with preform height reduction and forging time were recorded, plotted and analyzed.
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