Abstract
Production of forgings with stiffeners, which are made from aluminium alloys on a heavy-duty hydraulic die forging machine, can often lead to defects such as bursts, shrinkage holes and so on, which can also occur due to uneven deformation. To prevent such defects, certain process- and design-related techniques are used in actual production that help control the flow of metal across the die impression. The experience of designers and process engineers is not always sufficient for them to properly design the forging, the tool and the process, which makes experiments necessary. Due to advances in computers and software, which now enable to carry out virtual experiments and computer simulation, costly laboratory and field experiments are not relevant any more. For computer simulation of forming processes, most of steel and machine producers, both in Russia and abroad, rely on FEM software packages, which have the following features: a large amount of memory and a high speed of the user computer, long calculation times, a big size of the input file. The aim of this research is to create a simple and user-friendly simulation software package for modelling metal forging processes. The developed software package EQUI is used (so far) for computer simulation of the metal flow pattern and contains the following images: the workpiece contour, the metal flow boundary and the flow line. Using this software, the upsetting process was simulated. Physical experiments were carried out in which workpieces of the same shape were produced by upsetting. A comparison of the results of the computer and physical simulation confirms the suppositions suggested.
Keywords
Metal flow boundary, flow line, metal flow pattern, workpiece, upsetting, equidistant curve, computer simulation, software package.
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