Numerical analysis of a two-stage forming process for a hollow part with external flange

Abstract

Abstract This paper presents the results of a numerical analysis of a two-stage forging process for producing a hollow part with an external flange. The numerical analysis was performed via the finite element method using Deform-2D/3D. The analysed case included a cold forming process. The billet was a tube made of a low alloy steel grade 42CrMo4 with its flow curve described by a constitutive equation. The forming process involved the use of two operations: extrusion and forging in a tapered die cavity. The objective of the study was to determine whether the proposed forming technique could be used for production of hollow flanged parts. The kinematics of material flow, distributions of effective strains and the Cockcroft–Latham ductile fracture criterion, as well as force parameters were examined. The conducted research confirmed the correctness of the proposed method.