Physical modelling studies using spike forging to verify analytical predictions

Abstract

Combination processes are widely used in the metal forming industry. Spike forging, which involves both extrusion and upsetting type of flow, is an interesting process being applied in the industry for the manufacture of plates of desired shape with projections, such as in the case of camera levers. This process has been used to study material flow behaviour under forging conditions and to validate the analytical solutions developed for forging operations. Also, it has been used to study the die filling characteristics of hot forging lubricants. The purpose of the present study is to evaluate, experimentally, the flow behaviour during spike forging using a tapered top die and a flat bottom die. A further aim is to compare the experimental results with the results of an analytical model on the basis of the outer profile, the grid distortion and the strain distribution.