Abstract
To reduce the forging load of the proposed large deformation forging technology, a new type of forging system is proposed. In this forging system, the contact length between forging dies and a work can be reduced by adjusting the swing motion of the dies during forging. This swing motion results in load reduction because contact length is a dominant factor of the load for this type of forging. Also, this forging technology is relatively stable when using lubrication because of its basic up-and-down motion. In this study, load reduction effect with the newly proposed forging system and lubrication are examined by laboratory-scale experiments and FE analysis. It appears that a nearly 30% load reduction can be achieved by the swing-type forging compared with the flying-type forging under the condition of a large thickness reduction. Width spread is also reduced by the swing type forging because contact length has a large influence on a material's lateral flow. Moreover, another 20% to 30% load reduction is confirmed and seizure on the forging dies was prevented by lubrication.
