Abstract
Focusing on the rough forging stage of the hot free forging process, the influence of the operational conditions on the occurrence of concave defects was first numerically analyzed using a three dimensional rigid-plastic finite element method. The validity of the analysis was examined by laboratory experiments using lead billets and the analytical results are in good agreement with experimental results. As a result, the mechanism through which the concave defects appear was clarified, and it was revealed that by applying only a small curvature to a plane surface of an anvil, the concave defects is enormously improved. Moreover, it was found that the new anvil geometry makes it possible to increase the productivity.
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