Theoretical study of a new forging technology with additional macroshift using fem simulation in deform

In this paper the finite element method is used to simulate the process of forging round-section blanks in strikers of a new design. It is shown that the use of a radial joint of the faces has a positive influence on the hydrostatic pressure distribution along the entire length of the metal-tool contact. The comparative research of models with various values of flat zones inclination angles showed that the best variant is the tool with an angle value 30°. In this case a deep strain distribution over the cross section occurs in the billet with a significantly lower deformation force than when using tool with an angle value 0°. The simulation of the sequence of technological forging operations was also carried out. Two first compressions were performed with the workpiece turning at 90° to close possible internal defects. Then the angle of the turning is lowered to 45° and 30° in order to bring the cross-section shape closer to the round one.