Abstract

Forging is widely adopted manufacturing method in automotive machine parts, aerospace components due to the good quality, high efficiency and less scrap generated by the process in comparison to other manufacturing methods. After heat treatment it gives comparatively good mechanical properties and fine grains which are advantageous for components used in high load conditions. In metal forging, to get desired shape and properties of product parameters like material selection, design parameter optimization, process parameter optimization is implemented which will lead to good microstructure. In closed die hot forging, which is one of the oldest forging processes, deformation occurs on metals having temperature more than its recrystalline temperature. Deformation occurs between two dies to shape the metal in the die cavity under an external pressure. In this paper simulation of closed die forging of an automotive component carried out using commercially available Q form software package. Analysis of material filling, temperature and stress profile done using Q form. Various factors like workpiece temperature, initial die temperature, shape of the die-cavity, stress and strain-rate influence the forging process. Contact between die and billet during deformation induces stress on both die and workpiece. This stress has direct impact on metal flow, die filling and life of die. Strain rate also plays a vital role in metal flow, microstructure of the component. So, it is important to study the stress profile of the process in various stage to predict the optimize shape of the die cavity, temperature and load required for the process. Finite element simulation is the method by which the process can be carried out using a software package.

Keywords: Forging; Finite element analysis; Qform; Closed die forging