Numerical simulation of multi‐blow forging processes using the explicit time integration finite element method

Abstract

Describes simulations of impact forging processes. Uses the explicit time integration finite element method, which is based on direct time integration of equation of motion, to compute the deformation of the workpiece and the dies. Uses the program developed to simulate the copper blow test performed on a 350,000J counter‐blow hammer. The calculated result reveals a good agreement in the final deformed configurations between the experiment and the explicit simulation. In order to compare this with the explicit method, the implicit time integration rigid‐plastic finite element program considering the inertia effect is also applied to the copper blow test simulation. As a result of the copper blow test simulation using the explicit program and the implicit program, finds that the calculated results have good agreements in available plastic deformation energy, forging load and equivalent plastic strain distribution. Finally, applies the developed program to simulations of multi‐blow forging processes. Presents three major findings from the multi‐blow forging simulations: (1) the continuous analysis technique used for the multi‐blow forging simulations works well; (2) the blow efficiency and the forging load generated by blow operations can be analysed efficiently and simulated results coincide with previous experimental and analytical ones; (3) the geometrical configuration of the workpiece is closely related to blow efficiency.