Study On Morphology Of Deformation Of Inclusions In Upsetting Process

With the rapid development of modern industry it requires heavy machinery manufacturing industry to provide high quality large forgings. Heavy disk forgings occupy a large proportion of the large forgings, and it requires very high internal quality for heavy disk forgings. As the cost of production is very high, so it will cause great economic losses once scrapped. The inclusion defect is the main issue which is reflected in the production of the heavy disk forgings. Especially the plastic inclusions will turn into large area sheet inclusions, as the larger axial deformation in the process of upsetting. And it would led to excessive testing finally.In this paper, they models based on the rigid plastic finite element theory, and use deform2d, deform3d softwares to simulate upsetting process.Mainly reflected in:(1)It did structural analysis and thermal coupled analysis on the flat plate upsetting cylinder and upsetting cylinder with inclusion. The impact of the forging forming and the inclusion of deformation, caused by the temperature difference and friction, were investigated.(2)The impact, caused by the different cone angles and different cone diameter, was analyzed in the process of inclusion deformation.(3)By simulating six different programs of upsetting, it showed the internal deformation process of rough, the internal strain distribution and change of radial size of the internal impurity with changes of amount of draught in the process of different options.(4)Based on the similarity theory, it did qualitative physics experiment, and compared the physical test results and numerical simulation results. It could show that numerical simulation results and physical results were match, proving the rigorous of numerical analysis theory.