Abstract
The present work proposes a novel analytical solution for open-die forging for the billet of elliptical cross-section. From design and evaluation, moreover, from industrial prospective, in order to overcome the limitations and complexities of mathematical modelling for complex shape billets, the numerical simulation technique has also been demonstrated to establish and exploit the potential of commercially available finite element analysis (FEA) software. To start with, testing of fundamental material properties such as tensile and compressive tests have been simulated and validated against experimental data of aluminum alloy such as AA6063-T7 and AA6061, respectively. In a similar manner, the FEA simulation for a closed-die forging process has been carried out and validated against experimental result. Subsequently, a mathematical model for open-die forging having elliptical cross-section of billet has been derived with certain predefined assumptions. The potentials of FEA simulation for different materials such as aluminum alloy (AA6063), mild steel and brass, have also been investigated to justify the proposed analytical solution, which has been noticed to have less than 5% error. The intricacies involved in the simulations along with mathematical modelling have been discussed in detail in the present article.
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