M Sabeghi - Iran University of Science and Technology, Tehran ,Iran
F Javanroodi - Iran University of Science and Technology, Tehran ,Iran

Radial forging is a forging process in which one or two punches move axially causing a radial flow into a die cavity by means of which a flange is formed. This process is used in producing of pulley and gears on a shaft. In this study radial forging process is simulated by a 2D finite element method (FEM) on a produced laboratory specimen (AL 6061) and the benefits of FEM simulation such as time and cost saving is scrutinized. The effective parameters for this forging process are die corner radius (R), ring gap height (H), friction factor (m), work-hardening coefficient (n), die clearance and the speed of the punch. The effects of these parameters on the flange thickness ratio (h/H), the outer protruding shape ratio (D/D0), effective-strain, warping and reaction force are also investigated and results were compared with experiments and theoretical results to confirm the accuracy. It is shown that when the corner radius is larger, the outer protruding shape ratio (D/D0) is smaller, and vice versa and when the height of gap is larger the effective strain distribution is homogeneous and flowing of material is easier. By increasing of friction factor the flowing of material becomes nonhomogeneous and D/D0 becomes smaller. Punch speed has limited effects on strains. Increasing die clearance has slight effects on reaction forces.

Radial forging process, Finite element method, Parameters