Development of Computational Analysis Software for Determining Energy and Pressure Requirements in Open-Die Forging Upsetting

Abstract

Upsetting in open-die forging requires the estimation of loads, stresses, energy and pressure required as this helps to determine how viable the process would be along with the lifespan of the die. As a result, critical studies were carried out on materials to be worked upon and their properties, lubricants used to reduce friction, controlling the structure and proficiency of a software program suited for general forging design analyses with the help of the workpiece geometry. In a forging process, the software was used with chosen cylindrical and rectangular geometry data and it could be deduced that as height reduces, there is a rise in the pressing force required during the operation. During the forging process of both cylindrical and rectangular geometry it could be deduced that as height reduces, there is a rise in the pressing force required during the operation, in cylindrical cold forging energy required was about 190858.5194 kN/mm compared to schey theoretical result while hot working process needed energy of 36927.3607 kN/mm. While the rectangular forging process generated a result of 7765.4918 kN/mm during cold forging and 2310.1852 kN/mm during hot working. The outcomes of the analyses were found equivalent to those derived from theoretical methods. The creation of this software should reduce the amount of time engineers and operators spend on designing and testing in the workshop, improve the precision of sketches and designs, and finally get rid of mistakes made when selecting the data required for the design. Erroneous data can be prevented through early fault detection and correction, which lowers production costs and complicates operations.