The Research And FEM Simulation In The Upset Forging Process Of Double Frustums Sucker Rod

With the competition between international manufacture, the forming technology of economizing energy, accuracy and high efficiency becomes one of the current research trends of metal plastic forming field. The precision forging process replaces the traditional manufacturing process, which can economize energy and material, enhance the efficiency, improve the quality of products and reduce the cost. Sucker rod is the key part which links sucker machine on the surface to sucker pump in the well used in the process of the oil extraction. More and more new types of sucker rod are opened out progressively with the rapid development of petroleum exploitation enterprise. However, the dies of sucker rod are still designed by handwork and made by conventional methods that greatly restrict the application of the precision forming process. Apparently, the traditional technique will not meet the demands of companies. The forming laws of sucker rod precision forging, especially double frustums sucker rod, have not been investigated completely because of the complicated geometry of sucker rod, many influencing factors and plastic deformation with difficulty. It is very important to research the precision forging process of double frustums sucker rod considering the conditions of our petroleum industry development.With the fast development of computer hard and soft wares, finite element method (FEM) and computer graphics, the computer aided engineering technology based on numerical simulation is used widely in metal plastic forming field. The simulation of metal forming processes can be realized on the computer. The precision forging processes of sucker rod can be studied with 3-D FEM. The load needed in plastic forming process can be decided by simulation. The distribution of the stress and strain can be obtained in workpiece. The forming laws of workpiece can be predicted. The numerical simulation is a powerful tool for the processes and dies design. In recent years, it is the developing trend of metal forming technology to use advanced methods, such as numerical simulation, to solve the problem in industry.The precision forging process of double frustums sucker rod and its key process technology are researched in this paper by the way of numerical simulation and experimental study. By analyzing the forging process of double frustums sucker rod and using rigid visco-plastic material model and 3-D coupled FE simulation, the whole forging procedure are analyzed and simulated with finite element analysis software DEFORM. The results indicate the inner stress field, strain field, metal flowing law and forging travel-load curve during the forming procedure. The forming statuses, causation of defect of workpiece are predicted and so on. All of these results can offer a qualitative and quantitative theoretical basis in optimizing the forging process of sucker rod and prolonging the final forging die's service life.