Analysis of the hot radial forging process according to the finite element method

Abstract

The radial forging process (RFP) is an advanced technology that many scientists have recently been trying to optimize and improve in order to enhance the quality of products and save energy in manufacturing. However, controlling the process when employed on large products is very difficult due to the appearance of cracks. During RFP, a tube is repeatedly and continuously exposed to stroking and feeding. Thus, when the die comes into contact with the product, the rotational feed stops. Afterwards, when the hummers break contact with the tube, the axial and rotational feeds are applied simultaneously in order to obtain a good surface finish at a specific rotation angle feed. Implementing RFP is a costly and lengthy process largely done through trial and error. It depends on variables such as material temperature, rotation speed, rate of feed, parameters of die geometry, die pressure, and amplitude. Thus, a symmetric 3D model simulation has been conducted with commercial FEM software. The results include the cantors of residual stress (RS), strain velocity, and temperature. Equally, the contact forces have been measured as experimental results, and there is a good correspondence between the two types of results.