Analysis of polygonal blocks forging by dual stream functions (DSF) application

In forging operations the prediction of metal flow is animportant consideration. Analysis of three dimensional metal forming processes are likely to takelong time and in some cases inaccurate. In this paper, a mathematical model using dual stream functions and the upper bound method have been proposed to examine theplastic deformation behavior in the open die forging of polygonal blocks between two flat dies. The material was assumed to be rigid–plastic. In mathematical modeling a kinematically admissible velocity field was suggested for the plastic deformation. The velocity fieldderived from the newly developed dual stream functions can automatically satisfy the volume constancy and the velocity boundary conditions. The non-uniform velocitywas derived for simulating the inhomogeneous deformation and the effect of barreling during the forging. Using the present model, various effects offorming parameter such as the friction factor, reduction, number of sides of the polygonal blocks, etc. Upon thenon-dimensional forging pressure, forging force and barreling of the blocks were analyzed systematically and the results compared with other researcher’sanalytical and FEM software results and are shown good agreement. Although this effect can be easily included in a finite element method, the demandingamount of memory and the computer time by this method is more economical than the FEM approach

Analysis of polygonal blocks forging by dual stream functions (DSF) application Keywords:

Forging , Dual stream functions , Upper bound method , Barreling effect