1) The document summarizes a case study for forging a part made of C45 steel using finite element analysis to simulate the forging process. 2) The first die design attempt was unsuccessful, with issues like backflow and highly stressed points. The second die design attempt showed promising results with smooth material flow and an evenly distributed maximum stress of 130MPa. 3) Finite element simulations of the second die design indicated no issues, with optimal load and temperature distributions and a maximum required load of 21MN, within the press's 25MN capacity.

1. Manufacturing
Processes
Project: Forging of a part
PROFESSOR: DE MADDIS M.
STUDENTS: MAZZARIELLO G.
MURATI R.
ZURABISHVILI N.

2. Case Study

3. Calculations
• Category of steel used: C45 (group M1)
• 𝑉𝑝𝑎𝑟𝑡 = 949963.66 𝑚𝑚3 (from Solidworks)
• 𝑉𝑜𝑙𝑢𝑚𝑒𝑓𝑜𝑟𝑔𝑒𝑑 𝑝𝑎𝑟𝑡 = 𝑉𝑝𝑎𝑟𝑡 ∗ 𝐾 𝑝 =
1424945.49 𝑚𝑚3
• 𝑉𝑜𝑙𝑢𝑚𝑒 𝑒𝑛𝑣𝑒𝑙𝑜𝑝𝑒 𝑠ℎ𝑎𝑝𝑒 = 4180485.73 𝑚𝑚3
• Shape complexity factor
𝑆 =
𝜌∗𝑉 𝑓𝑜𝑟𝑔𝑒𝑑 𝑝𝑎𝑟𝑡
𝜌∗𝑉 𝑒𝑛𝑣𝑒𝑙𝑜𝑝𝑒 𝑠ℎ𝑎𝑝𝑒
=0,34
(we are in class S2)
• 𝐾𝑝 = 1,5
• Check the complexity factor
𝑉𝑒𝑛𝑣𝑒𝑙𝑜𝑝𝑖𝑛𝑔 𝑠ℎ𝑎𝑝𝑒
′
= π ∗
𝐷 𝑚𝑎𝑥
2
4
∗ 𝐻 𝑚𝑎𝑥 =
4205298.227𝑚𝑚3
• 𝑠′
=
𝑉 𝑓𝑜𝑟𝑔𝑒𝑑 𝑝𝑎𝑟𝑡
𝑉𝑒𝑛𝑣𝑒𝑙𝑜𝑝𝑒 𝑠ℎ𝑎𝑝𝑒
′ = 0,46
Performing the check we are still in class S2.

4. Flash Design
Bruchanow and Rebelski formula
𝑠 = 0,015 ∗ 𝐴 𝑓,𝑝 = 3 𝑚𝑚
𝐴 𝑓,𝑝 = 𝜋 ∗
𝐷2
4
= 40828.13 𝑚𝑚2
𝑏 = 9 𝑚𝑚

5. Tolerances

6. Design Of Dies
The tolerances were applied according to the European standard EN 10243-2. All the tolerances
were considered to be a feasible solution, but only the highest one suggested was applied all
over the case study in order to make the final process of machining easier.
•Machining clearance: 4 mm
•Tapered angles
• outer: 6 degrees
• Inner:9 degrees
•Fillets:
• Outer: 3 mm
• inner: 10 mm

7. Design Of Dies
•Material: steel C45, Group M1
•Complexity factor: S2

8. Attempt 1

9. Attempt 1
Negative outcome:
• Backflow
• Highly stressed points

10. Attempt 1
This die design was scrapped
after many unsatisfactory
simulations.

11. Attempt 2

12. Parameters
•Equipment: Mechanical Press 25MN
•Lubricant: Glass
•Temperature of workpiece: 1200 C
•Temperature of dies: 150 C
•Material of dies: H13 HRC50

13. Simulations – Velocity vector
Positive outcome:
• No backflows
• Smooth material flow

14. Simulations – Effective stress
Positive outcome:
• Maximum stress observed is 130MPa
• The effective stress is evenly distributed at
the end of the process

15. Temperature and Mean Stress

16. Finite Elements Mesh
The finite element mesh has the correct
distribution since smaller elements are used in
elevated deformation zones and near the
angles of the forged piece.

17. Load Graph
The maximum load needed does not exceed 21MN,
which is the best result among all configurations
already tried.

18. Final Part
The forged part has to undergo
machining to reach the final design
which is shown in the picture below.
The MUF is around 50%.