J. Inst. Eng. India Ser. C DOI 10.

1007/s40032-016-0236-y CrossMark

ORIGINAL CONTRIBUTION

Modeling of Closed-Die Forging for Estimating Forging Load

Debashish Sheth1 2 • Santanu Das3 • Avik Chatterjee4 • Anirban Bhattacharya5

Received: 12 May 2015/Accepted: 20 April 2016 © The Institution of Engineers (India) 2016

Abstract Closed die forging is one common metal forming

process used for making a range of products. Enough load is to
exert on the billet for deforming the material. This forging load
is dependent on work material property and frictional
characteristics of the work material with the punch and die.
Several researchers worked on estimation of forging load for
specific products under different process variables.
Experimental data on deformation resistance and friction were
used to calculate the load. In this work, theoretical estimation
of forging load is made to compare this value with that
obtained through LS-DYNA model facilitating the finite
element analysis. Theoretical work uses slab method to assess
forging load for an axi-symmetric upsetting job made of lead.
Theoretical forging load estimate shows slightly higher value
than the experimental one; however, simulation shows quite
close matching with experimental forging load, indicating
possibility of wide use of this simulation software.

Keywords Metal forming • Forging • Cold forming •

Closed die forging • Forging load • FEM

1& Santanu Das

sdas.me@gmail.com
2 Bharat Heavy Electricals Limited (BHEL), BHEL Site Office, Bellary TPP, Kudathini, Karnataka 583115, India
3 Kalyani Government Engineering College, Kalyani,
West Bengal 741235, India
4 CSIR-Central Mechanical Engineering Research Institute, Durgapur, West Bengal 713209, India
5 Indian Institute of Technology Patna, Bihta Campus, Bihta, Bihar 801103, India

Published online: 04 May 2016 1 Springer

ndrel was modeled [16], numerical simulation was done
] by Zhang andPtuothers forTotal forging
forging load at the upsetting
of differential satellite stage
r. FEM was also used [18] for designing die for making
ged bevel gears. Parting lines and their effects on axi-
mmetric forged parts were explored [19] in a work, when
d needed in multi-stage forging was calculated by others
].
In the work reported in this article, forging load is evaluated
oretically using the Slab method, and computed through
te element analysis (FEM). Validation of the estimated
ues has been tried with the experimental observation made
lier. Corresponding to the forging load, distribution of stress
valuated to find out presence of any unsafe stress.
remain constant at the interior portion of deformation zone I.
Different deformation zones are illustratedJ. in Figs.
Inst. Eng.3,India
4 and 5.
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Analysis of Stress and Load for Unit Deformation Zones
Entire deformation pattern during forging may be divided into
different unit deformation zones. Forging load is evaluated for
each zone considering stress distribution to be continuous.
Calculation of stress is done at zone 4 in the shaft, and zone 1
in the flange. Along neutral surface, stresses at both of its sides
are to be equal. Steps of calculation are undertaken [3, 4] as
outlined below.
Converging or Diverging Flow in Longitudinal Direction

rging of a Lead Disk with Flash
sed-die axi-symmetric forging of lead with flash around its
iphery is considered in the present work. Different stages of
ormation and their theoretical formulations are discussed in
following.
Converging flow of workpiece material occurs in the shaft
(zone 4) as shown in Figs. 3 and 4. The load, Ps, is needed to
extrude the shaft at the top surface of the flange. For longitu-
dinal diverging flow, angle (?as) needs be replaced by (—as).
Ps = nr]k4 ln(rs/(rs — hs tan as)) (1 )

where,
tal Flow and Deformation Stages
r z4 [/4 (1 + tan as) + tan as]
2

k4 = 2
tline of the die cavity is shown in Fig. 1. Stages of tan as
ormation are upsetting, filling, and end of forging [3] (Fig.
Theoretical modeling needs to simulate these stages of
ging. Several researchers [1, 3, 4, 17] analyzed stages of
ging following Slab method. In this work, estimation of
ging load at different displacements of

Fig. 3 Deformation zones and metal flow during filling stage

END
Fig. 2 Stages of metal flow in closed-die forging
nch is first made using a computer programme using Slab
thod.
The Slab (or Sachs’) method [3] assumes that stresses on a
ne perpendicular to the flow act in principal stress directions
deformation is homogenous through out different
ormation zones. The workpiece material is considered to be
ropic and incompressible. Elastic deformation is neglected.
rtia forces are quite small, and hence, neglected. Die is Fig. 4 Upsetting stage during forging
sidered to be rigid. Flow stresses, at are assumed [3] to

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Fig. 5 Deformation zones and metal flow during the end stage
rz4 = k4 ln((rs — z tan as)/(rs — hs tan as)), rz4 = axial
stress
J. Inst.distribution in the shaft due to converging flow; f4 =
Eng. India Ser.
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friction factor at the interface of dies and zone 4; rs = radius at
a point, s; hs = thickness at a point, s; as = angle of inclination,
or half the taper angle; z = 0, at the top entrance to the shaft.

Parallel Flow in Longitudinal Direction

Parallel flow occurs in zone 3 (Figs. 3, 4) in longitudinal

direction when upward metal flow occurs by shearing along a
cylindrical surface. Axial stress, rz3, is increased towards the
lower die according to:

r j
z d
= a -+ 4 r 3 z ( sdsi (2)

where, azb = axial stress at the top surface of deformation zone;

a3 = flow stress inside deformation zone; ds = diameter of
deformation zone; z = 0, at the top surface of deformation zone.

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Parallel Flow in Lateral Direction surface varies continuously during forging. The
Inward parallel flow occurs at the flange, inside neutral analysis is, hence, done in infinitesimal small
J. Inst. Eng. India Ser.
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surface, that is, zone 2. Axial stress, az2 is evaluated as steps of stoke, Ah. Variation of neutral diameter
r
z2 22
2r / (r R )/h
s 0 F rz3ave (3) is neglected for small step of stoke. Average
dimensions are used over surfaces defined by
where, r2 = flow stress inside zone 2; f2 = friction factor at dies
and zone 2 interface; rz3ave = averaged axial stress at the
diameters D0 and Dj. Considering metal flow
boundary of zones 2 and 3. during a step, one can determine instantaneous
Axial load, P2, over zone 2, is computed by: workpiece geometry. Inside neutral surface,
Rn
volume of metal flowing towards shaft, Av4 is
P2 = 2 rrz2dr (4) equal to volume displaced inward in zones 2 and
Rs
3 as the die advances by, Av23. Thus,
where, Rn is radius of neutral surface.
Outward parallel flow occurs at the flange, outside neutral
surface (zone 1). Axial stress, rz1 is calculated as:
ff
zi = 2rfi(Ro - r)/ho + ri (5)

where, a1 = flow stress inside zone 1; f1 = friction factor at die

and zone 1 interface.
So, axial load, P1, can be obtained from:
R
o
P1 = 2pi rrz1dr (6)
Rn
Converging Flow in Lateral Direction
(R2 - Rl) 2

Outward converging flow in lateral direction is occurred in Ri - + Ro

hi
zone 6. Axial stress, az6, is:
ff
z6 = -k2ln(k3 + rk1/(h/0))/k1 + rz5(r = RF) (7)

where,
k1 = —2 tan b
k2 = — r6 • k1 + 0.577r6 • 2(1 + tan2b) k3 = h0
+2 tan b • RD RD = RF — cu/ tan b
rz5(r= RF) = axial stress at r = RF calculated from zone 5; r6 =
flow stress inside zone 6.
Load P6 is obtained using Eq. 8.
RD
P6 = 2n rrz6dr (8)
RF
Upsetting Stage

The Geometry of Forging during Deformation

Neutral surface is the separating surface between zones 1 and

2. As upper and lower dies come together, material outside
neutral surface flows and increases diameter of the forging,
while material inside neutral surface flows toward the centre
and fills the shaft. Diameter of the neutral
Av4 = nAs(Rs — Hstanas)2 (9)
Av23 = nR^ Ah (10)
Since deformation is incompressible, volume calculated needs be equal. Thus,
AV23 = Av4 (11)

As = R2nAh/(Rs — Hs tanas)2 (12)

Similarly, volume displaced outside neutral surface is: Av 1 = P(RQ — R2) Ah, when Rn is radius at neutral surface.

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Volume of additional upset in flange cavity is: Avf = p(Rj —
RJ.
Q)h . Incompressibility
Inst.
1 Eng. India Ser. again gives: Avf = Av . 1

C
! 1/2
(13)
Using Eqs. 12 and 13, geometry of workpiece at a certain
step of stoke can be evaluated with a known location of neutral
surface.

Load and Stresses at Unit Deformation Zones

At the flange, metal is extruded into shaft, and metal flow can
be modeled. Actual flow model minimizes need of deformation
energy. At a stage, actual flow can be approximated with a
flow model that results in minimum axial stress acting at the
surface of the lower die cavity.

Determination of Location of Neutral Surface

Neutral surface is the boundary between zone 1 and zone 2. At

this surface, both axial stresses, aZl and rZ2, are equal for r = Rn.
From this condition,
Rn = [ri/1Ro + GoflRs + ho (ff1 — ffz3ave)/2]/fff1 + ^2
(14)
Total Forging Load for Upsetting Stage

Total forging load, Ptu at the upsetting stage is the sum of loads
necessary to extrude the shaft, Ps, to upset zone 1, P1, and to
upset zone 2, P2.
Thus, Ptu = P1 + PQ + PS (15)

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 To determine P1, P2 and Ps at each stage of deformation, it
is necessary to know the position of neutral surface R, forging
diameter D0, height of shaft Hs, and thickness h0. All these
dimensions vary with forging stoke. At each instant of stoke,
entire load and volume relationships are found, and results are
used for next step. This procedure is simulated in this work.
Excess metal is extruded into flash. Load and energy needed
help to reach final dimensions in axial J.direction.
Inst. Eng. This stage
India Ser.
needs either be eliminated or minimized. C
During a small forging stoke, dh, volume of displaced
metal, Avt, is extruded into flash. Thus,

Filling Stage

Corresponding to small step of stoke Ah, additional filling of

shaft outside the neutral zone is calculated as
vo = Av5 + Av6 + Avi = nAh (R - R^) (16)
Because of volume constancy, displaced volume outside of
the neutral zone must be equal to the additional extruded flash,
i.e., Av0 = Avf.

Estimation of Stress and Load

Towards periphery of flange, metal flows into flash by

shearing along a tapered surface. The position of this tapered
surface is obtained from shear angle, b (Fig. 3). Suitable value
of this angle should be such that axial stress at neutral surface,
rn becomes minimum. Then, shear angle is given by: 1.732(R -
If■
R ln R where, R = h0/hf0ff = friction factor at the flange.
Location of taper surface and neutral surface, Rn, are
.1 1/2
tan p = (17)
determined from the condition of r = Rn
and az1 = rz2. Thus,
R
n = [r1/1RD + rf2RS + h0( rz6(atr=RD) — rz3ave) / 2 ] /

[rf + rf] (18)

Stresses and loads are then calculated similarly as that of
upsetting stage. At an instance, deformation zone 1 is
eliminated, and neutral surface becomes the boundary between
zone 6 and zone 2. b is found to be 45 o giving minimum stress
distribution in zone 6.

Total Forging Load in Filling Stage

Total forging load during filling is the sum of loads needed at

each deformation zone.
Pt = P1 + P 2 + P34 + P5 + P 6 (19)

End of Forging

At the end of forging, the shaft is entirely filled in (Fig. 2) and

neutral surface has moved to the centre of forging.
Avt = nR^Ah (20)
Volume of additional extruded flash is:
Avf = n(R\ - R0)hf 1 (21)
Keeping volume constant, Avt = Avf, one gets Ri = [AhR2/hf i + R2]1/2. (22)
At this stage, height of flange, hf0, is such that metal flows
Complete Shearing in Die Cavity
easily consuming less energy, forming lateral shear surfaces.

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Geometry of flow model, and shear angle, b, are given below:
J. Inst. Eng. India Ser.
C = 0.8
h/hfo 0.92 (ho/hfo) (23)

t a n b = [1 - (R - 1)/(RlnR)]1/2 (24)
where, R = hlhf0,H = height of shear deformation zone; hf0 =
instantaneous flash thickness.

Shearing along Tapered Surface

At this case, Eq. 23 is not satisfied. In zone 1, metal flows by

sliding at the die-material interface. Load determined for
finished forging becomes maximum forging load. Capacity of
equipment needs be selected on the basis of this load [4].
Load-displacement curve during forging stages is shown in
Fig. 6 as obtained through simulation.

The Finite Element Analysis

Finite element analysis (FEA) of upset forging is done using

LS-DYNA software. The forged lead component is axi-
symmetric and billet size is /75 mm x 43 mm. Element for
meshing is 2-D, 4-node solid quadrilateral element (Plane 162)
with Lagrangian material continuum. Meshed model consists
of 500 elements and 1000 nodes (Figs. 7, 8).
Punch and die are modeled as rigid bodies. Young’s
modulus, Poisson’s ratio and density of punch and die are 17
GPa, 0.42 and 11.35 gm/cm3 respectively. Stress-strain
behaviour is assumed to follow power law plasticity model r =
Ken at a temperature, and it is strain rate dependent.

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Fig. 6 Load displacement curve from computer
simulation
Fig. 7 FEM mesh model of punch, billet and die
Fig. 8 Model of die, punch and billet
Here, strength coefficient, K of 7000 unit, and strain hardening
index, n of 0.04 are chosen.
For die and punch, only downward translation is possible.
Automatic contact option is applied between punch (parti) and
job (part2) and between job (part2) and die (part3). Automatic
contact algorithm automatically
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Time (min)
1
J. Inst. Eng. India Ser.
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Fig. 9 Loading curve- punch deflection in inch
with time in second
Fig. 10 Axial stresses in the billet for punch deformation of 0.08 in
determines contact surface orientation for shell
elements unlike the general algorithm. In
automatic contact, checks are made regarding
contact on both sides of shell elements. Viscous
damping coefficient chosen is 10.
A loading curve (as shown in Fig. 9) in terms of dis-
placement of punch in Y direction is given input for analysis.
Termination time for solution is taken 0.022 s. Axial stress in
Y direction at various stages of deformation is evaluated. At
certain regions, local high stresses are observed that are likely
due to severe distortion of elements in such region, and are
safely neglected. Adaptive meshing with Arbitrary Lagrangian-
Eularian formulation helps in easing out this hour-glassing
effect. However, it increases computational time. Average
stresses in billet at various regions are utilized to calculate
forging load at various sections. Sequential steps of
deformation along with stress distribution as obtained by
simulation are shown in Figs. 10, 11, 12, 13, 14, 15 and 16.
Bird’s eye views of these steps of deformation are shown in
Fig. 17. Forging load is then calculated from stresses. Load
displacement curve obtained using FEA is shown in Fig. 18.
 J. Inst. Eng. India Ser.
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Fig. 11 Axial stresses in the billet for punch deformation of 0.142 in Fig. 14 Axial stresses in the billet for punch deformation of 0.68 in
Fig. 13 Axial stresses in the billet for punch deformation of 0.5 in Fig. 16 Axial stresses in the billet for punch deformation of 1.18 in

Fig. 12 Axial stresses in the billet for punch deformation of 0.319 in

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Fig. 18 Load displacement curve using LS-DYNA code

Results and Discussion

Results obtained using Slab method and finite element analysis with LS-
DYNA software are compared with the experimental observation as reported
by Altan and Fior- entino [4], and are shown in Table 1 and Fig. 19. Experi-
ments were done on forging of lead samples of 75 mm diameter x 43 mm
height within lubricated dies with machine oil at room temperature. A
constant, uniform friction factor of 0.1 is assumed. It can be seen from Table
1 and Fig. 19 that comparable results are obtained within all the three
observations. However, forging load calculated through Slab method gives
somewhat higher values throughout stages of deformation than experimental
Table 1 Error of forging load estimates
Displaceme Experimentall % Error of % Error of
nt y obtained theoretical forging load
(inch) forging load forging load estimate
(ton) estimate through LS-
DYNA
0.1 17 35. 5.9
3
0.2 19 42. 5.3
1
0.3 21 66. 4.8
0.4 24 79.7 4.2
0.5 27 102 3.7
0.6 38 3.7
57. 5.3
0.7 63 17.9 3.2
0.8 146 23.5 2.7
0.9 232 7.83 1.3

values. This may be due to the assumptions taken while evaluating forging
load using Slab method. Although uniform, constant friction factor is

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 J. Inst. Eng. India Ser.
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a published literature, it may be stated that the Slab method of analysis gives 16. A. Ghaei, M.R. Movahhedy, A.K. Taheri, Finite element modelling simulation of
radial forging of tubes without mandrel. Mater. Des. 29(4), 867-872 (2008)
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shows analyzed stresses to be all safe. This shows applicability of this 578 (2008)
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Acknowledgments The present paper is an extended version of the paper titled 546-551 (2009)
‘Exploring Forging Load in Closed-Die Forging’ presented in 5 th International and 19. A. Fatemi, F.R. Biglari, M.A. Noghabi, B.M. Dariani, An analytical, numerical,
26th All India Manufacturing Technology, Design and Research (AIMTDR) and experimental study of the effect of the parting line position in the forging
Conference held at Indian Institute of Technology Guwahati, India during December process of axisymmetric parts with middle elements on one side. Proc. Inst. Mech.
12-14, 2014. Eng., Part B: J. Eng. Manuf. 223(10), 1315-1322 (2009)
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