DOI: 10.18503/1995-2732-2022-20-4-58-66
Abstract
The paper describes the development of a specific software suite applied to simulate a metal flow chart in hot forming processes of shaped flat bars. It contains an assessment of conventional kinematic metal flow diagrams: normal and radial ones. A virtual experiment conducted in DEFORM, showing good results in plastic forming, demonstrated that at any parameters of an upsetting process a real diagram was an “intermediate” metal flow kinematic diagram, consisting of zones of the flow along the normal to the circuit and zones of a radial flow. To develop an algorithm of calculating the flat bar upsetting parameters, it is assumed to consider as acceptable a normal kinematic diagram of a metal flow in friction conditions accompanying hot die forging and pressing of aluminum alloys with lubrication. Following this assumption, EQUI software suite was developed to simulate a metal flow chart along the contact plane of the tool and the bar. To carry out a computer simulation of a 3D contact stress drawing and, as a consequence, boundary lines of the metal flow, it is suggested to use KOMPAS automated design system, where a stress problem may be converted to a displacement problem. It is possible due to a projection of a solid model representing a similar 3D contact stress drawing on a plane of the contact between the tool and the bar, giving an image of the boundary line of the metal flow on the contact plane. The comparison of the results in KOMPAS and EQUI shows a good agreement.
Keywords
flat bar, forming, upsetting, metal flow chart, 3D contact stress drawing, friction coefficient, software suite
For citation
Solomonov K.N., Tishchuk L.I., Bakhaev K.V. Analysis of the Metal Flow Diagram in Flat Bar Forming Processes. Vestnik Magnitogorskogo Gosudarstvennogo Tekhnicheskogo Universiteta im. G.I. Nosova [Vestnik of Nosov Magnitogorsk State Technical University]. 2022, vol. 20, no. 4, pp. 58-66. https://doi.org/10.18503/1995-2732-2022-20-4-58-66
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