FEM simulation of C45 steel and Cu-ETP billet shaping at hot upsetting between convex conical dies

Abstract

Abstract On the basis of finite element analysis (FEA), geometric differences in the shaping during hot upsetting of cylindrical billets with a height-to-diameter ratio of 1.0 and 2.0 made of C45 (1.0503) steel and copper (Cu-ETP) between pointed convex conical dies with a cone slant angle of 12.5°, 15.0° and 17.5° are considered. The stroke velocity of the upper die is 0.5 m/s; process temperature (t) and accepted surface friction coefficient (|μ): for steel - t = 1100 °C, μ = 0.32, for copper - t = 850 °C, μ = 0.34. An equation is obtained for the relation between values of reduction in height ratio and engineering strain on height of workpiece during upsetting between conical dies, taking into account the initial billet dimensions and unevenness of forming due to the geometry of tool. The presence of qualitative and quantitative differences in shaping along the height of upset steel and copper billets was revealed, i.e. influence on unevenness of forming the rheological properties of materials under process conditions. It is advisable to use the results obtained to design and improve of technological processes of open die and closed die forging with preforming of billets.