| A comprehensive methodology to physically and numerically model upsetting in cold heading was developed.; The physical model was a Drop Weight Test with a guided pocket-die set capable of approximating industrial cold heading conditions. The results show that the test is sensitive to the critical parameters for cold heading. These include surface quality, residual element level, nitrogen content, microstructure, decarburization, and specimen geometry. The test is capable of assessing the fracture behavior of cold heading materials.; One goal of the study was to reveal differences in fracture behavior with varying steel sources. Accordingly, the matrix of test materials consisted of grade 1038 steels from three different steel sources.; Material preparation and conditioning of test materials approximated industrial procedures for cold heading materials. These procedures included hot rolling, controlled rod cooling, descaling, straightening, lime coating and lubricating, and wire drawing. Spheroidization of test specimens was performed in an industrial batch furnace using an industrial heat treatment cycle.; A finite element program (FEM) enabled the simulation of upsetting in cold heading. The inputs required to model the cold heading process include flow stress behavior and friction conditions representative of cold heading. These inputs were obtained using the CANMET Cam Plastometer and the Friction Ring Test.; The Cockcroft and Latham fracture constants for an as-rolled and a spheroidize annealed 1038 material were computed by FEM modeling and the critical values were calibrated using the Drop Weight Test. The fracture criterion constant was found to be independent of strain path for upsetting in cold heading and thus is material-related. |
