Deformation Force Calculation And Process Parameters Optimization Based On Model Element Method For Open Die Forging

At present, there are many methods to solve and optimal the plastic forming problem, the classical theory can be used to solve simple symmetric or plane analysis, and traditional experience design method is used in complex problems as open die forging. However, reasonable process parameters can not be accurate or feasibly designed because conceptual error is existed in experience design method. The new emerging finite element analysis method can not show the law between various parameters although the numerical solutions have the characteristics of intuitive and commonality. Therefore, it has practice significance to research open die forging and analyze process parameters in an appropriate method.Model element method is a generalized finite element method, it divide complex forming process into many related model units by the method of time-domain and unite division, then solve each model unit by classical theory, finite element method, experience method to achieve the purpose of solving and optimizing the whole complex problem.Model element method was used to study open die forging in this paper, mechanical model of open die forging process model units was built on the base of identifying mechanical characters, model building, forging analysis, dividing time-domain and model units. Element model was built, analyzed, solved in reasonable time-domain and various factors were analyzed to 1. each influencing factors was fitted by least square method and the effect of each influencing factor to open die forging was analyzed.2. compare the influence degree of each factor.The results were conclude by analysis and discussion:1. the initial volume of blank had greatest impact on the maximum forming force, full forging force, full forging energy consuming. So it was better to avoid the traditional principle of " better large not small", at the promise of full forging, chose appropriate blank size can reduce the forging force and energy consumption, and prolong the service life of die.2. The other factors as flash slot size, friction coefficient, the cavity depth, the most hard to fill corner radius, etc, had affection on forging process too, so appropriate parameters should be chose to get the optimum forging process.