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Materials
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ELSEVIER Journal of MaterialsProcessingTechnology60 (1996) 517-522

Spatial modelling of swaging process using finite element method applied to axially-symmetrical
problems
A. Piela, F. Grosman
Department of MetaUurgy and Materials Engineering, Silesian Technical University, Gliwice, Poland

Abstract
The analysis of hot volume-forming requires description of local changes occurring in the deformation gap including thermal, and
pretty otien also structural, phenomena. The most appropriate solution of analysis would be application of the Finite Elements Method
for a spatial model. Hardware requirements and times necessary to solve such a model are oRen unacceptable. Henee an attempt was
made to find such a solution that would make possible performance of calculations in practically acceptable time on available computers
(e.g. a SUN workstation). A procedure has been elaborated that enables application of the Finite Elements Method used in solving
axially-symmetrieal problems, for modelling spatial processes, for which the assumption of preserving flatness of cross-section during
the forming process can be made. Verification of the correctness of the elaborated method has been carried out for bars swaging process.
The paper presents a eoneept of a model of swaging with four fiat anvils. In calculations this model allows to take into account: the
deformation gap geometry, the course of the process as a function of time, the kinematics of tools and of the deformed metal movement,
thermomeehanieal conditions of forging. The simulated mechanical state of the deformation zone takes into aceount the specific character
of swaging process as well as non-proportional and non-monotonic increase of deformations.

Keywords: thermomechanical modelling, finite elements method, swaging process, hot volume-forming

I. Introduction a rectangular cross-section) are carried out by an appropriate way

Analyses of swaging processes presented in the literature in
most eases refer to swaging of round bars in shaped anvils. The
analysis of metal flow is carried out assuming axial symmetry of
stresses and strains in respect to the axis of a swaged bar.
Suggested theoretical solutions [1-4], elaborated on the basis of
simplified models of metal flow, are descriptive and do not
provide possibilities o f quantitative characteristics' determination.
At the same time a view is presented that tool geometry, the
shape of deformation gap, the magnitude of wrapping angle, the
magnitude of dratt and the feeding rate and the type of sizing
scheme affect the mechanical scheme of the process in a
substantial way [5, 6]. Hence it is vital to analyse the process of
metal flow in a swaging machine taking into account phenomena
occurring locally in the deformation gap as well as the effect of
technological conditions of the process course.
2. Physical model
Forging in a swaging machine for preliminary working with
four fiat anvils working simultaneously or alternatingly, using
various sizing schemes, enables manufacturing of bars with the
following cross-sections: square, rectangular, octagonal and
round. Sizing schemes: circle ~ circle, circle ~ square --- circle,
circle ~ square ~ octagon --- cirele (or other applied at forging
of material feeding between anvils. The way and the size of
feeding and the draR magnitude affect the geometry of the de-
formation gap (Fig. 1) and with the remaining technological
conditions of the swaging process determine the mechanieal state
of the deformation region. Metal flow in the deformation gap
results from numerous strokes deforming metal at simultaneous
continuous change of the position of any point within deformation
region in respect to anvils. The change of position is due to both
the metal flow itself and the movement of material feeding
between anvils. Because of the metal deformation method in a
swaging machine, irrespective of the type of sizing scheme, the
width of the material/tool contact surface increases along the
deformation gap (Fig. 1). At the same time the total material
wrapping by anvils angle ~O changes increasing from zero to
360" for closed anvils (Fig. lb). The length of the deformation
focus increases with increasing dratt. The load conditions of the
swaged bar vary along the deformation gap changing the
mechanical scheme of the process. Taking into account the
mentioned relations, significant in modelling the state of stress
and strain in swaging, requires application of spatial elements in
the FEM analysis. Application of FEM in a way making possible
carrying out simulation calculations in practically acceptable time
and using available computers imposes a necessity of designing
a simplified model of the swaging process because programmes
for spatial elements require substantial calculating times, even
when using computers with great calculating capacity.

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518 A. Piela, F Grosman / Journal of Materials Processing Technology 60 (1996) 517-522

a) The principle of preserving fiat cross-sections has been

material's plane m o t i o n niaterial's experimentally confirmed in trials of composed bars swaging,
V~ rolatiou
results of which have been presented by [7]. With this assumption
the linear strain along the axis of the forged bar is constant for
each cross-section element Sn_ I S n (Fig. 1) and results from the
cross-section reduction:
.........................Z - 2 Z Z
, t e s : In Sn-I : 2In Dn-1 : const (1)
S. Dn
.... anvil _/
According to the assumption of axial symmetry of load the
stresses in layers do not depend on the angular variable while the
perimetric stress a 0 = a0(r,z ) is the main stress, whereas the tan-
gential stress roz = rot = 0 (indices for cylindrical coordinates
r,z, ). In the analysed sector of a torus shown in Fig. 2 the
remaining stresses are functions of linear coordinates: or= or(r,z),
Oz=Oz(r,z), r,~ = r~(r,z).
lo,
~ bk
a)
c) G= (r,z)
Z
P ¢_

~~~-'~t 1 -
Fig. 1. Geometric scheme of the deformation gap at feeding
the material with: a) complex and b), c) simple movement.

Anvil
Therefore an attempt has been made to solve the problem of . i :!,g ~il ~i'.' ~:~iii:;~~:~:~..................
simulation of the state of stress and of analysis of the metal flow
seheme in the swaging process using the FEM solution for flat
elements and introducing assumptions enabling obtaining a spatial
solution. On the basis of results of own investigations on
simulation of the forging process in a swaging machine using 3D
elements [7] and positive results of simulation of metal flow in
the deformation gap, assuming preservation of flatness of cross-
sections of the deformed body and a generalized fiat state of
Fig. 2. Geometric scheme of slice-modelled deformation gap;
plastic deformation [8-10], a concept of process simulation by
a) circle --, circle sizing scheme, b) separated cross-sections on
means of finite elements method has been worked out for axially-
the length of the deformation gap.
symmetrical issues. This concept is based on the following
assumptions:
The displacement rate vector has got two non-zero components
* the deformation gap is modelled in layers (Fig. 2a), assuming
vr, Vz, that do not depend on the 0 coordinate, while components
a principle of preservation of fiat cross-sections in layers,
of the strain rate are described by the relations:
• the mechanical state in a freely separated cross-section of the
deformation gap (Fig. 2b) may be simulated, analyzing the
= - ~'Z = Dz,z~
axially-symmetrical problem of loading the material in a form r ' (2)
of a torus, with forces symmetrically distributed in relation to • : l(u • : •
e'rz ~ r,z + 19z.r)' er~ ez0 = 0
its axis,
*, the torus radius R > > D - the diameter of the deformed bar
(Fig. 2a), The presented simplification enables analysis of the spatial
• mass forces and forces of manipulator interaction have not deformation gap by considering fiat sections situated in
been taken into account in calculations, consecutive positions between the entrance plane of S O cross-
• the sizing zone 1k and the effect of stiff ends are neglected in section area and the exit plane of S k cross-section (Fig. 2 b). The
calculations, analysed layers originate from consecutive phases of torus
• a quasi-stationary method of problem solving has been deformation simulation from the initial diameter D o to the final
assumed. dimension D k, as presented by diagrams in Fig. 2 a.
 A. Piela, F. Grosman / Journal of Materials Processing Technology 60 (1996) 517-522 519

For a given type of swaging machine, with a beater stroke Displacement of the whole system: anvils - material is carried out
frequency equal to fu and the material feed between following during forging time t with a variable velocity vuk depending on
strokes equal to p = vp/fu, the length of deformation gap log changes of anvil's movement velocity expressed by equation (5).
depends on the slope of the anvil's working part ~r and on the Taking into account relations (4) and (5) and the geometrical
magnitude of drat~ per pass Ah what is expressed by the relation: relations presented in Fig. 3, the velocity of all the system
movement is described by the function:
Ah + vp (3)
l°g = T ctg % ~-u
AR R. - R._ 1 R . ( e "s- 1)
Vuk= - Vk = • 2~r fuv/~2 e - x (6)
The deformation gap is determined by cross-section shape t x x
profiles, varying along the deformation gap according to the
anvils' instantaneous position. The principle of fiat cross-sections The magnitude of strain e s occurring in the formula (6) is a
is satisfied if the torus radius increases with the deformation: function of anvils' instantaneous position x (Fig. 3). The
maximum deformation is determined by the draft in a single
R x = 1~ e ~ (4)
anvils' stroke for one feed p what is described by the relation:
Meeting of this condition requires that anvils, apart from the
Ah / v
movement connected with swaging, would displace in the radial Xmax - - P- tg% = p ' t g % (7)
2 lu
direction r (Fig. 2 a) according to the increase of current torus
radius R x. The movement of all the system anvil - material being
deformed, significant for modelling o f the mechanical state o f the When swaging square or octagonal bars (feeding the material
deformation gap, does not affect the result of calculations due to between anvils with a simple movement without rotation), the
mass forces that are neglected in calculations. The displacement magnitude of strain resulting from cross-section reduction is
velocity of all the system vuk (Fig. 3) is related to the anvils' described by relations, respectively for circle --- square sizing
movement velocity v k and to the draft magnitude Ah. These scheme:
values determine the forging time t and with the remaining times
related to material feeding and rotation time and to the time of "/7"
e = In
staying of the analysed cross-section outside the deformation
(8)
zone, decide about the correctness of the model in the field of
calculation of the band temperature field as well as the 4aros" +4" D._, D._,
rOn]
~D._I) j
displacement velocity field.
a)
and for square --, octagon sizing scheme:
Z Vu k

R,., =10' m ~ R I e = In 1 ~r n-1

,]
0.828 4- + (9)
lira

b)
I
r
2
- ( D ' - I ] • arccos
Dn
+ Do,)
~D ) D_ 1 D.)

Fig. 4 presents profiles of a forged bar cross-sections according

Theoretical ~% to sizing scheme circle --, square ~ octagon as well as changes of
possible path of I
anvil's pressure I J elongation magnitude in cross-sections separated on the length of
1 on the 1 ~ the deformation gap, calculated for swaging a square bar of size
Dn= 130.2 mm into an octagon using a draft All = 23 mm.
I l-4zL.- / V,
Anvil's movement velocity According to the model assumptions the graph in Fig. 4b presents
magnitudes of cross-section reduction occurring for a separated
plane as a result of single strokes of anvils, passing through the
Fig. 3. Modelling of the kinematics of tools' movement and of deformation gap. The magnitude of a cumulative strain is also
the material being deformed; a) relation between velocity of the presented in this graph. For swaging of round bars, when the
system vuk and the reduction of cross-section es, b) change of the material is fed with a plane motion and rotation (complex
forming rate versus instantaneous anvils' positions. motion), the magnitude of cross-section reduction of the layer
depends on the magnitude of draft per pass, the magnitude of
The linear velocity of the anvil's movement for crank swaging feed p and the angle of rotation between consecutive feeds.
machines depends on the eccentric size e, erankshaR rotational All these values, together with the ingot diameter determine
speed co and instantaneous anvil's position x, what is expressed the deformation gap geometry (Fig. 5). The magnitude of the
by the relation: cross-section reduction may be determined for each layer from
appropriate geometric relations or measuring the area of appro-
v k = 2 ~r f~ ~x ( 2 . e - x ) (5) priate cross-section using a planimeter.
520 A. Piela, F Grosman /Journal of Matertals Processing Technology 60 (1996) 517-522

Cross-sections profdes and magnitudes of cross-section reduction

a)
in layers separated along the deformation gap for a constant
distance between layers, equal to the feed size, are presented in
Fig. 6. Cross-sections profiles have been determined for a ~b 200
mm bar, deformed with the draft Ah = 40 mm, at the feed
magnitude p = 11.1 mm that corresponds to vp = 50 mm/s. The
magnitude of bar's rotation between consecutive anvils' strokes
~xu = 13" 20'.

l l 1 I

1,5 Cumulative t
elongation ~c
1,4 _ :.,. /-

b)
1,3
1,2
- P
~ /
7 -n Elementaryelon-[--
gation in layers
1,15
X
/ 1,0 ~.J ~,,IIm ----~
l,I0
\ ./
/ 1 2 3 4 5 6 l0 11 12 13
7 8 9

p
Cross-sections separated along the deformation gap length
1,05

1 2 3 4 5 6 7 8 9 10 11 12 13
Cross-sections separated along the defonnation gap lellgth
92,93
I I I I I I I I I i I
0 10 20 30 40 50 60 70 80 90
The length of cro:,s-section reduction zone Imml

Fig. 4 Deformations at forging according to the circle --- square

--- octagon sizing scheme; a) the magnitude of the cross-section
reduction in a layer, b) changes of the elementary and cumulative
elongation magnitude on the length of the deformation gap. @
1o~ Fig. 6. Cross-sections profiles and changes of the elementary and
cumulative strain of layeres separated on the length of the
deformation gap.

3. Discretisation of the physical model

To model the process of metal flow at swaging a commercial

computer programme FORGE2 [11], has been adapted. This
software is based on standard solutions of FEM problem,
consisting in determination, in the analysed area, of the velocity
n----- 3 2 1
field for the assumed incompressibility condition and for assumed
Separated planes boundary conditions as well as neglecting gravity and inertial
forces, and fulfilling the condition of minimum of functional ex-
pressing the total power of plastic deformation. This solution has
Fig. 5. Deformation gap at forging with flat anvils according to been described in a detailed way by [12-14]. In the solution
the circle --,. circle sizing scheme for a small magnitude of draft assumed the material being deformed is considered to be a rigid-
and large feeding rate. visco-plastic body with a constitutive equation given by the
 ,4. Piela. F Grosman / Journal of Materials Processing Technology 60 (1996) 517-522 521

Norton-Hoff relation [14] while the relation between the stress a) Max e = 0,242
deviator and the strain rate tensor is described according to the
Min e = 0,061
Levy-Mises law. The thermal phenomena that take place in the
deformation region including: heat generation as a result of
friction work and deformation work as well as heat loss in the
metal/tool contact zone and air cooling have been described in the
programme according to Fourier's equation [15].
The programme used in calculations at the assumptions made,
create a coherent model of simulation of the swaging process. :::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
===============================:::5::::::~:;:::5:::::::::~:;:::~:~::::::::::::::::::::::::::::::::::::::~.~
Taking into account the thermal conditions of deformation and
rheologieal characteristics of the material it simulates the scheme
of metal flow in the deformation zone. It also takes into account
local changes of properties versus local values of temperature, i! E< 0,15

deformation and speed of deformation. Phenomena of heat gene- 0,15 < g < 0,20
ration and loss, occurring during deformation, are determined in b) :~..:.,.'...
each ealeulation step for the current field of deformation rate ~',.-" 0,20 < E< 0,25
affecting changes of local values being determined. Modelling of
0,25 < 13< 0,30
technological conditions refers to discretisation of deformation
gap geometry, tool movement kinematics and description of g 0,30 < g
theological properties of the material being deformed, introduced
to calculations on the basis of plastometric tests results.
Calculations have taken into account the temperature of charge,
the temperature of anvils and surrounding air as well as time of
band transport from furnace to swaging machine, forging time Max e = 0,386
and time of given cross-section staying outside the forging zone. M i n e = 0,121
These times determine the distribution of temperature on the
band's cross-section before the following pass.

Fig. 7. Distribution of local strain intensities on the bar cross-

section. Sizing schemes: a) circle --- square, Ah = 23.2 mm; b)
4. Summary square --- octagon, Ah = 9.2 mm.

The presented method of swaging process modelling makes

possible determination of characteristics of stress and strain x o8 = 97 MPa
distribution, temperature distribution and the kinetics of metal a o8 = - 2 5 8 MPa
flow and swaging force [16]. To illustrate the eomputing
capability of the described method the result of simulation of a
bar swaging process according to circle square octagon sizing
scheme has been presented in Figs. 7+9.
Detailed results of investigations on simulation of metal flow in
the deformation zone for various sizing schemes have been
presented by [16-18]. The analysis of numerical calculations O 4 < -250
results has revealed that the character of metal flow in the
deformation gap as well as the magnitude and distribution of local -250 < 0 4 < -100
stresses depend on the mechanical scheme of deformation,
technological conditions of the process and characteristics of the i ~ . ~ -100 < (Y~ < 0
deformed metal. On the other hand the mechanical scheme of 0< 04< 50
deformation in swaging machines depends primarily on the sizing b)
scheme, the shape of anvils' surface, the magnitude of material 50 < O4
wrapping with anvils angle as well as anvils' movement and the
method of material feeding.
Assumptions of the model have been experimentally verified.
The obtained results of calculations have been compared with
results of trial forgings in operating conditions [16, 17].
Considering strain distributions results of calculations have been
compared with results of local strain measurements, determined Max o~ = 256 MPa
by the method of composed bars. The obtained temperature Min o# = - 2 2 6 MPa
distributions on band's cross-section have also been verified
comparing them with results o f pyrometric measurements of bars' Fig. 8. Distribution of stress component tr~ at forging according
surface temperature. Results of investigations have revealed to the square-octagon sizing scheme, a) draf~ Ah = 5.2 mm, b)
consistency with simulation results. dratt Ah = 13.2 mm.
522 A. Piela, F Grosman/ Journal of MaterialsProcessing Technology 60 (1996) 517-522
References
Max k = 0,53
Min k = -0,45
k <-0,5
:::::::::::::::::::-0,5 < k < 0
I o<k <0,5
0,5< k
Max k = 0,197
Min k = -0,59
Fig. 9. Distribution of the stress state coefficient k at forging
according to the square-octagon sizing scheme, a) draft Ah = 5.2
mm, b) draft hh = 13.2 mm.
Simulation of swaging process carried out on the basis of the
deformation gap modelled in a layer way creates foundations for
a rational choice of forging technology, taking into account
technological safety of the process as well as requirements in
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