Theoretical and experimental analysis of the effect of die shape on the internal quality of forged rods

A statistical analysis of the scatter of strain intensity values and local forging reduction ratio values has been performed in the study, owing to which an optimal shape of hot blacksmith forging dies and technological forging process parameters assuring the homogeneous mechanical properties of forgings can be achieved. The aim of the study is to propose an optimal shape of dies to be used in the process of ingot blacksmith forging and to determine proper technological parameters which will assure the homogeneous mechanical properties of forgings to be obtained. Moreover, an analysis of data for strain intensity and local forging reduction ratios on the forging cross-section, depending on forging parameters and the shape of dies used, has been carried out in the study. To this end, investigation in the following scope has been performed in the study: performing computer simulations of the hot blacksmith forging of round rods on steel shaped dies for the two-dimensional model of this process, determining the effect of the applied methods of forging of round steel rods on the state of strains in the forgings, determining the effect of deformation region shape during forging and selected technological parameters of the forging process on the degree of homogenization of strain intensities and local forging reduction ratios. The results of theoretical investigation were verified by experimental tests covering the same scope, with lead being the model material in the tests. (C) 2004 Elsevier B.V. All rights reserved.