How to simulate the flow of metal using software and design die for close forging

1. METAL FLOW SIMULATION AND DESIGN
DIE FOR CLOSE FORGING
Presented By-: RAVINDRA JONDHALE
Guided By-: R.E.GITE
Topic Name-:

2. CONTENT
▶ Introduction
▶ History
▶ Process modeling input
▶ Flow chart for modeling of close die forging
▶ Finite element simulation
▶ Result and discussion
▶ Advantages
▶ Limitation
▶ Scope for future work
▶ conclusion
▶ Reference

3. INTRODUCTION
Simulation is the imitation of the operation of a real-world process or system
over time.
The application of computer aided design and computer aided
mfg.(CAD/CAM) technique to gaining popularity as a resulting productivity
improvements are becoming more and more apparent Most users are using
CAD/CAM.
CAD system for closed die forging design. This system includes the facilities
for drawing the die geometry, simulation of the deformation process and die
analysis under forming conditions.
To overcome the problems occur such as large deformation and displacements
which cause certain computational problems, so that algorithm has been
developed. Types of simulation are
1) monte carlo simulation
2) continuous simulation
3) discrete event simulation
4) finite element simulation

4. HISTORY
▶ ENIAC and the Monte Carlo Method.
▶ In the mid-1940s two events laid the foundations for the
rapid evolution of the field of simulation:
▶ The construction of the first computers used for specific
purposes, such as the ENIAC (Electronic Numerical
Integrator and Computer).

5. LITERATURE REVEIW
SR
NO
NAME OF
AUTHER
TITLE YEAR DESCRIPTION METHDOLOGY CONCLUSION
1
1)Manas
Shirgaokar
2)Gracious
Ngaile
3)Gangshu
Shen
Process
Modelling in
Impression-
Die
Forging Using
Finite-Element
Analysis
2005 Development of finite-element (FE)
process simulation in forging. the
development of remeshing methods and
the advances in computational
technology have made the industrial
application of FE simulation practical.
Commercial FE simulation software is
gaining wide acceptance in the forging
industry and is fast becoming an integral
part of the forging de-sign and
development process.
Computer
simulation is
reducing the
costs and time in
process
Development.
2
Marek
Hawryluk
Joanna
Jakubik
Analysis of
forging defects
for selected
industrial die
forging
processes
2016 The main goal of this paper is to identify
defects in forgings in selected die forging
processes.
The major problem is the formation of
underfills due to air pockets between the
forging and
the tool.
The improper
position of the
preform (the lever
forging
simulation) and
the improper flow
of the material
(the yoke forging
simulation) have
been identified as
the causes of
defects.

6. SR
NO
NAME OF
AUTHER
TITLE YEAR DESCRIPTION METHDOLOGY CONCLUSION
3
1)Hongacho ji
2)Jinping liu
3)xiaobin fu
New method
for mfg. of
hollow valve
by rolling
&forging also
numerical
analysis
2015 Using finite element method we find
distribution of effective strain, metal flow
Temperature force and torque are
analysed
Numerical results are then verified in
experiment under laboratory condition.
In this study
accurate 3D
model of the
CWR forging of
hollow valve was
developed using
deform 3D.
4
1)Mohammad
Omari
2)Mohammed
Hayajneh
Development
of a CAD/CAM
system for
simulating
closed
forging
process using
finite element
2010 The purpose of this paper is to study the
effect of the height and diameter of the
dies as well as work-piece dimensions,
on stresses and strains on dies in the
forging process. This helps in developing
a better understanding of the effect of
process parameters.
This study was
meant to be a
universal step in
developing a
CAD/CAM system
to design,
simulate, and
manufacture
metal forging
processes using
statistical
analysis.

7. SR
NO
NAME OF
AUTHER
TITLE YEAR DESCRIPTION METHDOLOGY CONCLUSION
5
1)miklos tisza
2)zsolt lukacs
3)gaszton gal
Numerical
Modelling Of
Hot Forming
And Heat-
treatment Of
Annular
Gears
2012 the theoretical background of metal
forming simulation including the basic
constitutive equations, and the
information flow in process modelling.
The important process variables and the
main characteristics of various hot
forming processes will also be discussed.
finite element
simulation can
successfully
applied in
modelling of bulk
forming
processes to
develop adequate
process
sequences and
die design, die
cavity filling, for
predicting
process limits.

8. ▶ Preventing flow-induced defects such as laps and cold shuts
▶ Predicting processing limits so that internal and surface defects are avoided
▶ Predicting temperatures so that part properties, friction conditions, and die
wear can be controlled
▶ Investigation of the effect of friction on metal flow
▶ Define Environmental, Die And Workpiece Temperature
1. PROCESS PARAMETERS
PROCESS MODELING INPUT

9. 2. GEOMETRIC PARAMETER-:
 The starting workpiece geometry and the die geometry need to be
defined in a closed-die forging modelling.
 Depending on its geometrical complexity, a forging process can be
simulated either as a two-dimensional, axisymmetric or plane-
strain, or a three-dimensional problem
 A typical starting workpiece geometry for a closed-die forging is a
cylinder.
 design the die using 3D software and open it into simulation
software
3D View of Die Part Developed system i.e. Upper die, lower die and billet

10. ▶ Material parameters are usually a function of temperature
▶ The material parameters for heat transfer modeling are the thermal
conductivity,heat capacity, and emissivity of the workpiece and die
materials.
▶ defined a function of strain, strain rate, temperature, and possible starting
microstructures.
▶ The Young’s modulus,the Poisson’s ratio as a function of temperature ,and
the thermal expansion of the die materials are important parameters for die
stress analysis
3. MATERIAL PERAMETER-:

11. 4. INTERFACE CONDITIONS (FRICTION AND HEAT
TRANSFER)-:
▶ The friction and heat-transfer conditions between the die and the billet have
a effect on the metal flow and the loads required to produce the part.
▶ the high contact stresses in between the workpiece and the die, the constant
shear friction factor is considered
▶ In compression tests it is possible to estimate the heat-transfer coefficient,
flow stress and friction as a function of temperature, strain rate, strain, and
forming pressure.
▶ The friction conditions change during the process due to changes in the
lubricant and the temperature at the die workpiece interface.

12. FLOW CHART FOR CLOSED-DIE FORGING

13. FINITE ELEMENT SIMULATION
1.Mesh generation-:
• FEA uses a complex system of points called nodes which make a grid called
a mesh.
• This mesh is programmed to contain the material and structural properties
which define how the structure will react to certain loading conditions
• Nodes are assigned at a certain density throughout the material depending on
a stress levels of a particular area.
Fig 5.1 Meshed system at the beginning of the simulation process

14. RESULT AND DISCUSSION
▶ the diameter of work-piece 80mm and height is 97.930 so that
▶ Workpiece dimension ratio is 0.77
▶ The another settings were taken: die height (H) was set to 55 mm
▶ The die diameter (D) was set to 30 mm, 50 mm and 70 mm.
▶ Finally, Table the design of experiment matrix showing the inputs (die
and work-piece dimensions) and the corresponding maximum outputs
(effective stress in MPa and effective strain in mm).
▶ finally draw a the load and effective stress results obtained for the
parameter settings of simulation run number according to Table 6.2

15. Run no. die Workpiece
R
Work “KJ” Effective stress
on upper die
“MPa”
Effective strain
in upper dieD “mm” H “mm”
1 30 55 0.77 92 1674 0.00700
2 50 55 0.77 92 1504 0.00630
3 70 55 0.77 92 1454 0.00608
4 30 75 0.77 92 1730 0.00720
5 50 75 0.77 92 1453 0.00610
6 70 75 0.77 92 1363 0.00570
7 30 95 0.77 92 1680 0.00703
8 50 95 0.77 92 1297 0.00543
9 70 95 0.77 92 1335 0.00559
Sr.
no
Workpiece diameter
X “mm”
Desired workpiece
Height Y “mm”
Actually used workpiece
height y=1.06×Y “mm”
Workpiece dimension
ratio R=X/Y
1 80 97.930 103.8 0.77
Table 6.1 the studied dimensions of the work-piece and corresponding ratios
Table 6.2. Design of experiment matrix shows different inputs and corresponding
maximum value of output

16. Two-dimensional simulation result of effective stress on upper die for run number
2, QformTM

17. Simulation result of load on upper die for run number 2, QformTM

18. Pareto chart of the effects of correlations and interrelations of the examined factors on the
effective stress
Pareto chart of the effects of correlations and interrelations of the examined factors on the
effective strain

19. ADVANTAGES
▶ generating the physical response of the system at any location.
▶ Safe simulation of potentially dangerous, destructive or impractical load
conditions and failure modes.
▶ Optimal use of a model. Often, several failure modes or physical events can be
tested within a common model.
▶ The visual representation of a wide variety of physical parameters such as
stress or temperature
▶ Extrapolation of existing experimental results via parametric analyses of
validated models.
▶ Relatively low investment and rapid calculation time for most applications

20. DISADVANTAGES
▶ It can handle only forgings whose cross-sections that is axisymmetric and plane
strain.
▶ for the analytical studies necessary to improve these values and thus make the
system more independent and reliable.
▶ temperature is not included in the finite element simulation code.
▶ it can only handle just the process under isothermal conditions.
▶ although the forging process is carried increases the temperature of the billet
this increase in heat is produced as a result of plastic deformation.

21. SCOPE FOR FUTURE WORK
▶ Develop prediction for time and die-gap at which filling of cavity takes
place so that over-squeezing is minimized.
▶ Predict temperature rise in work-piece so that energy of heating can be
reduced.
▶ Optimum blocker stage design based on FE analysis.
▶ Die life prediction and improvement, based on die stress analysis.
▶ Other complex component shapes can be undertaken for metal flow
analysis.
▶ Forging stage reduction in complex components processed in multiple
stages.

22. CONCLUSION
▶ The application of computer in forging industry continues to increase this is
mainly due to
▶ The demand by the customers for forgings using electronic geometry transfer.
▶ Increased emphasis on quality, reproducibility and shorter delivery schedules.
▶ Savings obtained by automatic design, drafting and NC machining of forging
dies
▶ computer simulation is reducing the costs and time in process development.
▶ The metal flow prediction and the grain flow in actual component.
▶ The die filling prediction in terms of contact element behavior is found useful
in real life situation.
▶ The billet temperature, flash thickness and friction are found to have a
significant effect on the forging load.

23. REFERENCE
▶ TheMohammad omari (2009), “Development of a CAD/CAM system for simulating
closed forging process using finite element method”, EC 26, 3
▶ Maria kapustova (2009), “Analysis Of Drop Forging Closed Die Using Computer
Simulation, VEGA 1/3192/06
▶ Manas Shirgaokar ,Gracious Ngaile ,Gangshu Shen(2005) Process Modelling in
Impression-Die Forging Using Finite-Element Analysis (#5104G)
▶ Marek Hawryluk , Joanna Jakubik (2016) Analysis of forging defects for selected
industrial die forging processes. 396-409
▶ Hongacho ji, Jinping liu , xiaobin fu (2015) New method for mfg. of hollow valve by
rolling &forging also numerical analysis. 2401-11
▶ Hao chen, Yanjin guan, fujun kou (2009) Numerical simulation and metal flow analysis
of hot extrusion process pp. 170-177