A Study Utilizing Numerical Simulation and Experimental Analysis to Predict and Optimize Flange-Forming Force in Open-Die Forging of C45 Billet Tubes

Abstract

Open-die forging holds a pivotal role in shaping machine parts within industrial applications. This study focuses on the assessment of stress–strain curves for C45 material at different elevated temperatures and strain rates through numerical simulations employing the finite element method (FEM). Specifically, the research investigates how the flow curve of materials at elevated temperatures and individual strain rates impacts the forming force during the flange forming of C45 billet tubes. By comparing the simulation results with experimental data on the flange-forming force, this study observes that optimal outcomes arise when considering both elevated temperature and strain rates in the flow curve of materials. The study then conducts simulations for C45 billet tubes with varying upsetting ratios (H0/D0), (S0/D0), and the punch’s pitch angle (α), aiming to address optimization challenges related to the flange-forming force. Consequently, a mathematical model is developed to represent the relationship between the flange-forming force and geometric parameters (H0/D0, S0/D0, and α). This model accurately predicts the forming force under various flange-forming conditions, demonstrating high precision with a maximum error of 4.26% compared with the experimental results. This study significantly contributes to the advancement of flange-forming technology in open-die forging through numerical simulation, enabling the optimization of the flange-forming force and the selection of appropriate equipment. These findings pave the way for more effective and efficient industrial processes, fostering innovation and progress in the field.