A Parametric Analysis of Deformation of Workpiece in Closed Die Forging

Under filling and folding are two major defects, resulting in defective parts at the forging stage or failure during service life. Folding may act as a potential starting point, for crack initiation and under filled components are straight way rejected, being unusable for further processing. In the present work, an effort has been made to study the quality of forged, components by variation of billet shape, size, temperature and coefficient of friction. The output parameters observed and analyzed were normal stresses, shear stresses, effective stress, effective plastic strain, effective strain rate, die wear, load and material flow rate. It was observed that, homogeneity of deformation was higher in small parts with deep die cavity, compared to big parts. Round billet shape was found to be most suitable for reducing die wear, effective strain rate and increasing material flow rate. The flash allowance of 10% was sufficient, to fill the die cavity, completely without folding when a round billet of proper size was selected. The paper gives an insight, into the generic design of the forging process, which could help in optimizing the forging process in industry.