AFDEX TUTORIAL 3:

AUTOMATIC MULTISTAGE STAGE HOT FORGING

PROCESS (3D)
 HOT FORGING PROCESS
Forging and Hot forging
• Forging, it is a manufacturing process in which workpiece is shaped by applying compressive
forces on workpiece. Types of forging are Cold and Hot.
• It is distributed according to temperature at which operation is performed.
• Hammers or presses are used most commonly to deform the part into high strength part.
• The hot forging this forging is carried out at a temperature above the recrystallization
temperature of the metal.
• The recrystallization temperature is defined as the temperature at which the new grains are
formed in the metal.
• This kind of extreme heat is necessary in avoiding strain hardening of the metal during
deformation.
 HOT FORGING PROCESS
Benefits of Hot Forging
• Good ductility
• Possibility to manufacture
customized parts
• Excellent surface quality
• High formability ratios
• Decreased yield strength and
thus less energy required
• Increased diffusion and thus
reduced chemical
inhomogeneity.
Different Materials Used Applications
• Structural steels •screw presses
• Aluminum and magnesium •hydraulic presses
wrought alloys
•drop, power drop or
• Free-cutting steels counterblow
• Stainless steels hammers
• Titanium alloys •crank presses, ring
• Molybdenum alloys rolling, cross rolling
• Nickel/cobalt alloys
• Most of the steel alloys are almost
always hot forged, because as
work hardening on hard materials
advances, their deformation
becomes more and more difficult.
 HOT FORGING PROCESS
Advantages and Disadvantages of Hot Forging:
The Advantages of Hot Forging
• High strain rates and hence easy flow of the metal.
• Recrystallization and recovery are possible.
• Forces required are less.

The Disadvantages of Hot Forging

• Lubrication at high temperatures is difficult.
• Oxidation and scaling occur on the work piece.
• Poor surface finish.
• Lesser precise tolerances.
• Possible warping of the material during the cooling process
 LEARNING OUTCOMES FOR TUTORIAL 3

How to
interpret the
What are the simulation
various possible results
How to enter manufacturing theoretically
the various defects during
How to simulate forging forging
cold forging parameters in
process software
STEPS FOR TUTORIAL 3
 PRE PROSESSING

Step1 Step 2 Step 3 Step 4

• Add cad • Add • Add • Solve

model material process
parameters
PROCESSING

Step 1 Step 2

Check Run
POST PROCESSING
INTERPRETATION– (FINAL WORK PIECE)
PROBLEM STATEMENT
MULTI STAGE HOT FORGING PROCESS
PROCESS INPUT INFORMATION
IMPORTING CAD FILE
IMPORTING FLOW STRESS INFORMATION
INPUTTING DIE VELOCITY INFORMATION
INPUTTING FRICTIONAL CONDITION
ADDING STAGES
APPLYING SPECIFIED INPUTS
INITIALIZING DIE POSITION
SPECIFYING SYMMETRIC PLANES
INPUTTING PROCESS INFORMATION
STROKE_STAGE-1
INPUTTING PROCESS INFORMATION
STROKE_STAGE-1
INPUTTING VOLUME COMPENSATION FACTOR
STAGE-1
SET INITIAL TEMPERATURE STAGE-1
INPUT PROCESS INFORMATION STROKE_STAGE-2
INPUT PROCESS INFORMATION STROKE_STAGE-2
INPUT PROCESS INFORMATION STROKE_STAGE-2
INPUT PROCESS INFORMATION STROKE_STAGE-2
INPUT PROCESS INFORMATION STROKE_STAGE-3
INPUT PROCESS INFORMATIONSTROKE_STAGE-3
EXECUTE SIMULATION & STORE FILES
EXECUTE SIMULATION & STORE FILES
CHECK POST PROCESSING