Team 12 presented their forging simulation and analysis of a nominal part. They created sketches, models, and calculations of the part, billet, and mold. Simulations using billet heights of 172mm and 177mm were unsuccessful, but 171.97mm was successful in the 2D simulation. The 3D simulation also succeeded and showed adequate material flow between the dies with the lowest mean stresses near the bottom of the part. The final 3D simulation confirmed the required forging load of 49.96MN matched the theoretical calculations.

1. TEAM 12
S277693 Mustafa El Akkad
S274143 Bahlul Bahlulzade
S274272 Dogukan Demir
S274266 Sevenay Kazanci

2. NOMINAL PART
DRAWING

3. NOMINAL PART SKETCH

4. NOMINAL PART MODEL

5. PRELIMINARY EXCEL CALCULATIONS

6. PARTING LINE CONFIGURATION
The parting line has been decided to be passing through the appointed
origin to favor the fillet design.

7. TOLARENCES
TABLE 1 FOR LENGTH, WIDTH AND HEIGHT TABLE 3 FOR THICKNESS

8. TOLERANCE CALCULATIONS FOR FORGED PART

9. FORGING DRAFT ANGLES
The angle of 6 degrees has been adopted as the standard
draft angle, with exception of one 2 degrees angle, for better
forging and, as a result, reduced mean stress.
FORGING FILLET RADII
All edges and corners were expected to
have fillets added to them. Sharp edges, as
known, can cause premature die failure due
to high stress concentrations, hence these
fillets are critical for a smooth material flow
and thorough filling.

10. FORGED PART SKETCH AND COMPLEXITY FACTOR

11. FORGED PART MODEL

12. FLASH DATA

13. BILLET MODEL
H=172mm
D=445mm

14. MOLD MODEL
Upper Die
Lower Die

15. FORGED LAYOUT

16. INITIAL SIMULATION SETUP
Temperature: 1200 °C
Distance: 0 mm
SIMULATION TYPE:
2D Forging
120MN

17. The height of the billet Hg was calculated to be 177mm using Method 1 in MS Excel, with a Kp factor of
1,06 and a h/d ratio of 0.40.
UNSUCCESSFUL

18. Now using Method 2, the value came out to be 167mm, with a fullness
correction factor of 0,5 and a h/d ratio of 0.38.
UNSUCCESSFUL

19. Because neither of the values satisfied the forging test, it was decided to take the
average of the values from Methods 1 and 2. Their average measurement is
171,97mm, with a h/d ratio of 0.38.

20. 2D SIMULATION RESULT WITH Hg=172mm
SUCCESSFUL
The forged piece has no unfilled cavities, as
seen in the video above, and a small amount
of metal has flown in the flash. As a result, the
volume of the workpiece has been precisely
defined.

21. 3D SIMULATION RESULT
SUCCESSFUL

22. FINAL SIMULATION SETUP
Temperature: 1200 °C
Distance: 0 mm
The simulation was repeated with the same billet size but
instead using 50MN hydraulic press and H13 HRC50 tool
material.
SIMULATION TYPE:
3D Forging

23. 3D SIMULATION VIDEO – MEAN STRESS

24. The material flow between the dies was shown to be adequate in the above test. The lowest
mean stress values are found near the bottom of the forged piece. This parameter's highest
values were found in the gutter.
MEAN STRESS IN THE WORKPIECE

25. FLOW LINES ARRAY ANALYSIS VIDEO

26. COMPARISON OF 3D FORGING SIMULATION
It is apparent that utilizing a 50MN hydraulic press reduces mean stress substantially.
50MN 120MN

27. The final 3D simulation results clearly reveal that the required forging load is 49.96MN, which conforms to the
theoretical number found on MS Excel. This is due to the filling of the cavity's final details.
Load-Time graph of the forging operation
Effective Work graph of the forging operation

28. PLASTIC STRAIN
The final structure of the part was free of defects. The
material flow was outstanding, and the dies were properly
filled.

29. DISTRIBUTION OF THE TEMPERATURE