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This paper explains the methodology of developing an open die-forging model using Deform-3D software to simulate the hot forging process on Ti-6Al-4V billet used in aerospace applications. Three-dimensional finite element model of an open die-forging model was designed in the Deform-3D software. To complete the simulation run, it comprises three modules, namely, pre-processing, simulation and post-processing. During pre-processing module, as per open die-forging process setup requirement two dies and one billet has been created using the standard data of forging. Suitable temperature conditions of Ti-6Al-4V material varying from 500°C to 1000°C are applied to billet. After the simulation had run with 100 steps, during post-processing step effective stress and strain, total velocity and displacement, final temperature was recorded. From results, it was observed that with increasing forging temperatures at 500°C, 750°C and 1000°C of hot Ti-6Al-4V billet – effective stress and strain were decreased, total displacement and velocity were decreased and the final temperature was increased. Deform-3D software will be used for finite element simulation to predict the metal flow behaviour effectively, during the forging process.

FINITE ELEMENT SIMULATION OF Ti-6Al-4V BILLET ON OPEN DIE FORGING PROCESS UNDER DIFFERENT TEMPERATURES USING DEFORM-3D