An analysis of upset forging of square blocks considering the three-dimensional bulging of sides

Kim, J.H.; Yang, Dong‐Yol

doi:10.1016/0020-7357(85)90033-2

Cited by 8 publications

(3 citation statements)

References 7 publications

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“…Due to uneven metal flow in upsetting, bulging is formed around the billet's center. In addition, cracks are peculiarly prone to generating on the bulged billet surface [4,5]. Restraint bulging is always a hot topic in the study of upsetting, especially for billets with a large height-to-diameter ratio (LHDR), which is defined by an LHDR value above 2 in this article.…”

Section: Introductionmentioning

confidence: 99%

Simulation and Experiment Study on Cone End Billet Method in Upsetting Billet with a Large Height-to-Diameter Ratio

Fan,

Liu,

Liu

et al. 2023

Applied Sciences

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A novel upsetting method, called Cone End Billet Upsetting (CEBU), is proposed in this paper to control bulging during the upsetting of large height-to-diameter ratio (LHDR) billets. This new upsetting method is mainly characterized by prefabricating a conical shape at the billet end, which aims to reduce the friction effect between the billet end and the anvil. In order to validate CEBU, the metal flow characteristics during upsetting of LHDR billets with traditional upsetting (TU) and CEBU were analyzed and compared by the finite element method. Experiments were also carried out to examine the deformation characteristics and microstructure of pure copper samples. The results show that, compared with TU, CEBU has a great advantage in restraining bulging and enhancing the compaction effect of upsetting. Meanwhile, bulging can be eliminated in CEBU with a 50% reduction ratio. In addition, aided by the cone end, the metal flow is no longer sensitive to the friction effect at the billet end. From the point of view of restraining bulging, a small taper angle is necessary prior to use. Furthermore, to avoid instability deformation, the height-to-diameter ratio of the billet should be below 3.0. CEBU is effective in suppressing the generation of bulging, but it also increases the pre-forming process for the end of the billet. The study on CEBU in this article is under laboratory conditions, and exploring the industrial application of CEBU will be the focus of our future research.

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Section: Introductionmentioning

confidence: 99%

Simulation and Experiment Study on Cone End Billet Method in Upsetting Billet with a Large Height-to-Diameter Ratio

Fan,

Liu,

Liu

et al. 2023

Applied Sciences

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“…In upsetting, due to the friction effect between anvil and billet, metal flow around the billet end is largely constrained which leads to generating a rigid deformation zone in this region [1 -3]. The rigid deformation zone not only affects the compaction ability of upsetting, but also leads to bulging [4,5] and surface longitudinal cracks [6,7], which seriously affect the forming quality of the billet. In particular, for the billet with height-diameter ratio above 2.0 which is generally named large height-diameter ratio (LHDR) billet, bulging is inevitably emerged after the traditional upsetting method [8].…”

Section: Introduction mentioning

confidence: 99%

Virtual Orthogonal Optimization in Upsetting of Cone End Billet with Large Height-To-Diameter Ratio

WANG¹,

Fan

Zhao

et al. 2023

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To restrain bulging in the upsetting of the larger height-diameter ratio (LHDR) billet, a novel upsetting method named cone end billet upsetting (CEBU) is proposed in this article. This method is featured by prefabricating cone shape at billet ends, and aimed to obtain a smaller rigid deformation zone in forming. The forming characters of a cylinder LHDR billet were analyzed by the commercial finite element software DEFORM. Moreover, virtual orthogonal tests were proceeded to uncover several influence factors such as billet end taper, pressing speed and billet height. The results show that bulging can be effectively restrained in CEBU. In the condition of billet end taper α = 15°, pressing speed υ = 0.5 mm/s, and billet height h = 35 mm, a much smaller bulging can be achieved. The simulated results are in good agreement with experiment which was conducted with polycarbonate samples, and indicate CEBU is a promising method to control bulging in the upsetting of LHDR billet.

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“…But computation time should be reduced considerably in order to solve more complicated upset forging problems. Very recently Kim (1985) analyzed upset forging of square blocks by using a simple velocity field with in a reasonably short computational time. In this paper a kinematically admissible velocity field for the threedimensional deformation in upset forging of elliptical disks is proposed which takes into account not only the sidewise spread in the plane perpendicular to the upsetting axis but also bulging along thickness.…”

Section: Introductionmentioning

confidence: 99%

An upper-bound solution for forging load of an elliptical disc

Phogat¹

2012

J. Mech. Eng. Res.

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The present work critically emphasize on the deformation limit of an elliptical disc. The upper-bound theorem has been used to determine the forging load. A suitable kinematically admissible velocity fields for three dimensional deformations have been chosen for analyzing deformation limit as well as the bulging of disc. During the analysis satisfactory friction factor, yield strength and other process parameter have been assumed and mathematically analyzed. It has been seen that parametric and experimental analysis makes very close agreement. This paper will be worthy for industrial applications in estimating forging load of such shapes.

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An analysis of upset forging of square blocks considering the three-dimensional bulging of sides

Cited by 8 publications

References 7 publications

Simulation and Experiment Study on Cone End Billet Method in Upsetting Billet with a Large Height-to-Diameter Ratio

Simulation and Experiment Study on Cone End Billet Method in Upsetting Billet with a Large Height-to-Diameter Ratio

Virtual Orthogonal Optimization in Upsetting of Cone End Billet with Large Height-To-Diameter Ratio

An upper-bound solution for forging load of an elliptical disc

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