Elastic-plastic finite element analysis of semi-hot forging dies

Halisçelik, Murat
Semi-hot or warm forging is an economical alternative to the conventional forging processes by combining advantages of hot and cold forging processes. In this study, a new forging process sequence and design of the preform die for a part which has been produced by hot forging are proposed to be produced by semi-hot forging. Thermo-mechanical finite element analyses are performed over the stages of forging process. The billet and the dies are modeled as elastic-plastic bodies. Effects of preform die geometry on the die stresses and the forging load are investigated using finite element method. Comparison of the results obtained by using two different commercial finite element analysis programs is done for semi-hot and hot forging temperature ranges. The forging temperatures are determined for the particular part and the experiments are conducted by using the 1000 ton forging press. The parts are produced without any defects and material wastage in the form of flash is reduced. The numerical results are also compared with the experimental results and a good agreement is achieved.


Design and thermo-mechanical analysis of warm forging process and dies
Saraç, Sevgi; Gökler, Mustafa İlhan; Department of Mechanical Engineering (2007)
Forging temperature is one of the basic considerations in forging processes. In warm forging, the metals are forged at temperatures about the recrystallization temperature and below the traditional hot forging temperature. Warm forging has many advantages when compared to hot and cold forging. Accuracy and surface finish of the parts is improved compared to hot forging while ductility is increased and forming loads are reduced when compared to cold forging. In this study, forging process of a part which is ...
Analysis of warm forging process
Aktakka, Gülgün; Darendeliler, Haluk; Department of Mechanical Engineering (2006)
Forging is a metal forming process commonly used in industry. Forging process is strongly affected by the process temperature. In hot forging process, a wide range of materials can be used and even complex geometries can be formed. However in cold forging, only low carbon steels as ferrous material with simple geometries can be forged and high capacity forging machinery is required. Warm forging compromise the advantages and disadvantages of hot and cold forging processes. In warm forging process, a product...
Effects of induction heating parameters on forging billet temperature
Durukan, İlker; Gökler, Mustafa İlhan; Department of Mechanical Engineering (2007)
Induction heating is one of the efficient and modern technique for heating raw materials for hot forging process. The induction heating furnaces use electro-magnetic field to transfer energy to the metal workpiece and heat is generated inside the material. The magnetic field can be provided by using induction coil. The power supplied to induction coil, the moving speed of the billet that is called conveyor speed and the coil box hole diameter are the factors affecting the resultant temperature of the heated...
Friction analysis in cold forging
Cora, Ömer Necati; Akkök, Metin; Department of Mechanical Engineering (2004)
Friction is one of the important parameters in metal forming processes since it affects metal flow in the die, forming load, strain distribution, tool and die life, surface quality of the product etc. The range of coefficient of friction in different metal forming applications is not well known and the factors affecting variation are ambiguous. Commercially available FEA packages input the coefficient of friction as constant among the whole process which is not a realistic approach. In this study, utility o...
Experimental and numerical analysis of compression on a forging press
Biçer, Gökhan; Gökler, Mustafa İlhan; Department of Mechanical Engineering (2010)
Forging is a metal forming process which involves non-linear deformations. Finite element and finite volume software programs are commonly used to simulate the process. In these simulations, material properties are required. However, stress-strain relations of the materials at some elevated temperatures are not available in the material libraries of the related software programs. In this study, the stress-strain curves have been obtained by applying the Cook and Larke Simple Compression Test to AISI 1045 st...
Citation Formats
M. Halisçelik, “Elastic-plastic finite element analysis of semi-hot forging dies,” M.S. - Master of Science, Middle East Technical University, 2009.