Reverse The Upsetting Forging Process Research

Upsetting is one of the most basic forging processes. During casting, the ingot havemany casting defects such as voids, segregation, and inclusions, which have great influenceon the quality of steel ingot forging. The traditional smooth anvil upsetting can change theingot into the desired shape and size, but internal defects of ingot can not be overcome, andthe hardly-deformed sections are relatively large. It is not conducive to break the ingot-castmicrostructure, and the thick cast microstructure does not obtain good mechanicalproperties. This paper studies the torsional upsetting technology which can effectivelyreduce the hardly-deformed area so as to improve the quality of forgings.The present paper adopts the method of finite element numerical simulation to conducta simulation study of torsional upsetting process on30Cr2Ni4MoV steel by making use ofnumerical simulation software of DEFORM-3D. Firstly, the process of torsional upsettingand that of traditional flat anvil upsetting are compared in three aspects which aredeforming force, hard-to-deformation region and the average equivalent strain, to prove thesuperiority of the torsion upsetting process. Furthermore, the influences imposed ontorsional upsetting process by the process parameters are analyzed. The thesis also designeda four factors and three levels of orthogonal experiment, and the priority of factors and theoptimal combination of process parameters of the experimental program are finalized.In order to conduct a further study of torsion upsetting process, this paper designed aset of torsion upsetting device. The main features of the device are follows:(1) With thepushing action of the hydraulic press, forging twisting and upsetting are completed at thesame time.(2) The device push rod is provided with a plurality of pin holes, the torsionangle can be adjusted to meet various needs.(3) The torsion units is installed with acylindrical roller thrust that can withstand the pressure of350kN.(4) This device is simplein structure and is also flexible. Finally, the author conducted a physics experiment inreversing the upsetting device with the casting of lead ingots, to further test the superiorityof reversing the upsetting process.