Abstract

Preform design in flashless forging of three geometries of H-shaped finisher dies for both non-work-hardening and work-hardening materials is investigated by the finite element method. Design procedure uses the application of simulation methods of forward loading and backward tracing. It was shown that one preform each is required for the rib height ( H) to width ( B) ratios of 1.0, 2.0, and 3.0 for non-work-hardening materials, and that one preform is required for H/ B = 1.0, two preforms for H/ B = 2.0, and three preforms are necessary for H/ B = 3.0 for work-hardening materials. An extensive use of the backward tracing scheme in the design procedure resulted in an alternative design for the case H/ B = 3.0 for the work-hardening material where only two preforms are necessary to satisfy the flashless forging condition. The design details of all the blocker dies used for preforming operations are also determined.

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