In the present study, a new complex methodology for the analysis the closure of voids and a new forging system were developed and tested. The efficiency of the forging parameters and the effective geometric shapes of anvils to improve void closure were determined. A new cogging process provided a complete closure of an ingot’s axial defects, as confirmed by experimental tests. The evolution behavior of these defects with different sizes was investigated during the hot cogging process by means of the professional plastic forming software Deform-3D. A comprehensive procedure was developed using the finite-element method (FEM) for the three-dimensional cogging process and laboratory experimentation to predict the degree of void closure. The hot multi-pass cogging process was used to eliminate void defects in the forgings so as to obtain sound products. In the compression process, the effects of the reduction ratio and forging ratio, the void size, and the types of anvil were discussed to obtain the effective elimination of a void. For the purpose of the assessment of the effectiveness of the void closure process, the following indices were introduced: the relative void volume evolution ratio, the relative void diameter ratio, and the internal void closure evaluation index. Moreover, the void closure process was assessed on the basis of stress triaxiality, hydrostatic stress, forging ratio, value of local effective strain around the void, and critical reduction ratio. The results of this research were complemented by experiments predicting the formation of fractures in the regions near the void and in the volume of the forging in the course of the cogging process. The comparison between the predicted and the experimental results showed a good agreement.

The paper presents the analysis of the three-dimensional strain state for the cogging process of the Ti-6Al-4V alloy using the finite element method, assuming the rigid-plastic model of the deformed body. It reports the results of simulation studies on the metal flow pattern and thermal phenomena occurring in the hot cogging process conducted on three tool types. The computation results enable the determination of the distribution of effective strain, effective stress, mean stress and temperature within the volume of the blank. This solution has been complemented by adding the model of microstructure evolution during the cogging process. The numerical analysis was made using the DEFORM-3D consisting of a mechanical, a thermal and a microstructural parts. The comparison of the theoretical study and experimental test results indicates a potential for the developed model to be employed for predicting deformations and microstructure parameters.Keywords: hot forging, titanium alloy, finite element method, microstructure evolution W pracy przedstawiono analizę przestrzennego stanu odkształcenia dla procesu kucia wydłużającego stopu tytanu Ti-6Al-4V z wykorzystaniem metody elementów skończonych z założeniem sztywnoplastycznego modelu odkształcanego ciała. Przedstawiono wyniki prac związanych z symulacją schematu płynięcia metalu i zjawisk cieplnych w procesie kucia na gorąco w trzech rodzajach narzędzi kuźniczych. Rezultaty obliczeń umożliwiają określenie rozkładu intensywności odkształcenia, intensywności naprężeń, naprężeń średnich i temperatury w objętości odkuwki. Rozwiązanie uzupełniono o model rozwoju mikrostruktury podczas kucia. Analizę numeryczną wykonano z wykorzystaniem programu DEFORM-3D, składającego się z części mechanicznej, termicznej i mikrostrukturalnej. Porównanie teoretycznych i eksperymentalnych rezultatów badań wskazuje na możliwość zastosowania opracowanego modelu do prognozowania odkształceń i parametrów mikrostruktury.

The paper describes the analysis of the three-dimensional stress and strain state for the process of elongation forging of the X37CrMoV51 die steel using the finite element method. The results of simulation studies of the metal flow pattern and thermal phenomena in the hot forging process carried out in three different forging tools are reported. The results of the studies have been complemented with the prediction of the occurrence of ductile fractures during forging. The numerical analysis was performed using the DEFORM-3D program. The comparison of the theoretical study and experimental test results indicates a possibility of applying the developed model to the examination of strains and prediction of material fracturing during the hot forging of die steel.Keywords: hot forging, damage, shaped anvils, FEM W pracy przedstawiono analizę przestrzennego stanu odkształcenia i naprężenia dla procesu kucia wydłużającego stali narzędziowej X37CrMoV51 z wykorzystaniem metody elementów skończonych. Przedstawiono wyniki prac związanych z symulacją schematu płynięcia metalu i zjawisk cieplnych w procesie kucia na gorąco w trzech różnych narzędziach kuźniczych. Rezultaty badań uzupełniono o prognozowanie powstawania pęknięć ciągliwych podczas kucia. Analizę numeryczną wykonano z wykorzystaniem programu DEFORM 3D. Porównanie teoretycznych i eksperymentalnych rezultatów badań wskazuje na możliwość zastosowania opracowanego modelu do badania odkształceń i prognozowania pękania materiału podczas kucia stali narzędziowej na gorąco.

Abstract. Analytical model of temporary and residual stresses for butt welding with thorough penetration was described assuming planar section hypothesis and using integral equations of stress equilibrium of the bar and simple Hooke's law. In solution the effect of phase transformations (structure changes and structural strains) has been taken into account. Phase transformations during heating are limited by temperature values at the beginning and at the end of austenitic transformation, depending on chemical composition of steel while the progress of phase transformations during cooling is determined on the basis of TTT-welding diagram. Temperature values at the beginning and at the end of transformation are conditioned by the speed of heating. Kinetics of diffusional transformation is described basing on Johnson-MehlAvrami-Kolmogorov equation, while martensitic transformation, basing on KoistinenMarburger equation. Stresses in elasto-plastic state are determined by iteration, using elastic solutions method with changeable longitudinal modulus of elasticity, conditioned by stress-strain curve. Computations of stress field have been conducted for one-side butt welded of two steel flats made from S235 steel. It has enabled a clear interpretation of influence of temperature field and phase transformation on stresses caused by welding using Submerged Arc Welding (SAW) method.