Objective

Forging simulation-
Cold forging (2d) simulation of cylindrical part in an
open die.
3D CAD Model of Component
Isometri Top
c View

Bottom
Side
View
View
Die Design Details
Isometri Top
c View

Side Bottom
View View
 Material Properties Dia. 100
mm

Component Material Properties

Name: Cylindrical Part (Cold Forging)

Material Temperature : 25 deg. Cel.

mm
80
Billet Size: Dia. 100mm x 80mm Lg.

Billet (work piece) front

before forging
Process Parameters

Press Details:
1 mm/s Tabular motion (Upper
Die)
0 mm/s Tabular Motion (Lower
Dies)
Movement Range 40 mm
Lubrication :
Lubricant with coefficient of
friction 0.2
Meshing Details
Mesh Details
Element Type :
Tetrahedron Number of
Elements
Initial
Final : 719
Number of
Nodes Initial
Final : 782

Solver Settings
Solver Details
AFDEX : A3DCS_2014_SP1 (3D
Non_isothermal)
Results
Effective
Strain Rate
Min :
0.0022

Max :
0.0738
/s

Effective
Strain Min:
0.02
Max: 1.5
Results
Von
Mises
Stress
Min : 627.2 MPa
Max : 899.2
MPa

Principal Stress
Min : -500.2
MPa
Max : 644.5
MPa
Results
Flowlin
e

Nodal Velocity
Min : 0.000
mm/s Max :
1.00 mm/s
Results
Foldin
g

FOLDING IS
NOT APPLICABLE FOR 2D
SIMULATION

Under
fill
Results

Load vs Time, Min: 0 kN, Max: 3272.85 kN (Maximum Load is observed in

the Lower die)
Observations
Excessive barreling of product-

Reason- Due to the cylindrical profile of initial preform, it results in

barreling of product.

Solution- Design the initial preform for a fixed reduction so that the
barreling in the final product in minimized .

Present
Proposed