Abstract
In this study to develop the process design of the extended forging process, the deformation behavior during flat-die forging has been investigated in detail. Regarding the square of the cross section, the relationships between forging conditions (initial forging shape, feed rate and reduction rate) and deformation are clarified on the basis of the results of 3D-FE analysis and the actual experiment. First, to improve the analytical accuracy, the laboratory equipment determined the sizes of the test bars that were heated. The cross section of the forging shape of the test bar was measured. Using this result, the coefficient of friction based on the analytical condition is determined. Using this analytical condition and an analytical model, in which the shape is the same as that of the actual specimen, the equation for predicting the forging shape is constructed, and it is confirmed that the prediction equation can be applied to actual forging. Using this relational expression, the equation for predicting the forging shape has been developed. The reduction of the next forging pass using the actual dimensions (thickness and width) can be calculated by employing the process design using this equation.
