Abstract
An approximate solution for nonisothermal upset forging is presented. A finite difference thermal analysis and an upper-bound deformation solution are used for this purpose. The thermal analysis is for a homogeneous state of strain, it ignores deformation heating, but accounts for all modes of heat flow during the transfer of the billet to the tooling and throughout the deformation. The upper-bound solution is based on admissible velocity field equations, the recorded temperature data from the thermal analysis, and constitutive equations for temperature, strain, and strain rate-dependence of flow stress. The size of the chilled zone is determined by minimization of total power for the deformation process. Theoretical predictions for load-displacement behavior and the size of the chilled zone are compared with the experimental results for 304 stainless and AISI 1042 steels.
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