Numerical Analysis of the Die Forging of Porous Blanks in a Die with the Implementation of Active Friction Forces

Abstract

This paper provides the results of simulating the hot die forging of porous powder preforms with active friction forces applied along the lateral surface of the blank under deformation due to internal cohesion in the die–material system. The study covers the evolution of the distribution of the relative density over the blank cross section at different stages of deformation, the stress-strain state, and the total strain force while varying the boundary loading conditions by changing the initial compression force applied to elastic elements that prevent the die from displacement. It is shown that the active friction forces that act on the periphery of the forged piece adjacent to the die inner side result in areas with a significantly higher deformation intensity compared to deformations in the center of the blank volume. In this case, the volume of the high deformation intensity area and the maximum values of deformation increase with a decrease in the initial compression force of the springs and, accordingly, with an increase in the die displacement value during the deformation. The automatic displacement of the die due to the internal cohesion in the die–deformed material system leads to a decrease in the total deformation force, and the deformation force increases with a decrease in the die displacement value during deformation.