Simulation And Numerical Investigation Of Corrugated Component Forging Process Without Pre-Form Using Arbitrary Lagrangian-Eulerian (Ale) Formulation, And Prediction Of Rupture Using Ductile And Shear Damage Model

Forging is a manufacturing process in which metal is pressed, pounded, or squeezed under great pressure into high-strength parts. This is usually done by heating the metal, but some forgings are produced without heat. In forging, an initially simple part—a billet, for example—is plastically deformed between two tools (or dies) to obtain the desired final configuration. Thus, a simple part geometry is transformed into a complex one, whereby the tools “store” the desired geometry and impart pressure on the deforming material through the tool/material interface. The physical phenomena describing a forging operation are difficult to express with quantitative relationships. The metal flow, the friction at the tool/material interface, the heat generation and transfer during plastic flow, and also the relationships between microstructure/properties and process conditions are difficult to predict and analyze. In this paper, a ۳D model of forging without preform employing a die with sinusoidal profile using ALE formulation has been simulated by finite element method to study the feasibility of the process, deformation of the blank, distribution of stress, shear and Mises stress contours, distribution of spatial displacement contours and contour of equivalent plastic strain in the process. Two damage models, coupled with von Mises plastic criterion, have been applied to predict where and when ductile and shear rupture occur in the process. All studies presented in this paper have been carried out on aluminium alloy EN AW-۷۱۰۸ T۶.

Keywords:

Corrugated Component Forging , Without Pre-Form , Arbitrary Lagrangian-Eulerian , Aluminium Alloy EN AW-۷۱۰۸ T۶ , Ductile Damage Model , Shear Damage Model.