Abstract
The results of studies of energy-power indices (contact face pressure, work of deformation) during upsetting with buckling of relatively high workpieces with upsetting ratio 3.5 to 6.0 are summarized in the paper. The relation between work of deformation at the bulk buckling and edging ratio, and similar shape ratios was established. The results are shown that buckling pass is an energy-efficient way of workpieces shaping for bent forgings or dual-forming of some products and belong to the class of dieless (impression-free) bulk pre-forming process.
Highlights
Upsetting and bending are the most common operations in press-forging industry
We propose and investigate a brand new bulk forming process, such as pre-forming of workpiece for subsequent open die or closed die forging by upsetting of billet with large ratio of height L0 to diameter D0, followed by buckling
The investigation of energy consumption and its comparison with the edging ratios as a measure of workpiece pre-forming is relevant for the selection of manufacturing equipment, design of dies and evaluation of items of energy costs in the production of forgings
Summary
Upsetting is mostly performed as pressing between two flat dies, the dies should still be regarded as a pressing deforming tool that has contoured working faces or impressions which provide the necessary shape to the product after pressing. The processing of cylindrical workpieces by not contoured dies in manufacturing is more common. The investigation of energy consumption and its comparison with the edging ratios as a measure of workpiece pre-forming is relevant for the selection of manufacturing equipment, design of dies and evaluation of items of energy costs in the production of forgings
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