Body Diameter To Resolve The Forging Process Analysis And Numerical Simulation

Radial forging is an open forging process for reducing the diameters of shafts, tubes, as well as for creating internal profiles for tubes such as gun barrels. Radial forging process can improve the strength and fatigue property of the tubes as the residual compressive stress exists. Analysis of radial forging process using analytical method and numerical method is very necessary as the physical process is very complex during radial forging process.Analytical method is used to create the function to describe the stress,strain and deformation property during the radial forging process. The effect of process parameters on forging load is analyzed by a concrete example. The reliability of result is verified by the experimental results from the references.The 2D axisymmetric FEA model is created by the commercial finite element code Abaqus to analyze the metal flow and deformation of the tube. Besides that, the strain and residual stress are investigated and the minimum back pressure is proposed.An entire 3D FEA model is created to investigate the metal flow in radial,circumferential and axial directions. The effects of the spindle speed on the forging load and translation between the forging load calculated by 2D and 3D FEA model is considered.Both mathematical analytical model and FEA model of the vibration system consisted of the work-piece and the spring bar are created. The movement of the work-piece and the determination criteria of the torsional stiffness are discussed. The results can provide the theoretical basis to design the spring bar for the actual process.A 3D axisymmetric FEA model is bulit to simulate the deformation of the barrel rifling during the radial forging process and metal flow during the rifling forming process is analyzed. Additionally, the influence of the mandrel and the percentage of reduction on deformation are investigated in order to optimize the process parameters.The service life and fatigue property of the die and mandrel are analyzed by the commercial code Fatigue and the stress is also investigated.