Study of forging design using slip-line fields

The main purpose of forging design is to ensure cavity filling with minimum material wastage, minimum die load and minimum deformation energy. Given the desired shape of the component and the material to be forged, this goal is achieved by optimising the initial volume of the billet, the geometrical parameters of the die and the process parameters. It is general industrial practise to fix the initial billet volume and the die parameters using empirical relationships derived from practical experience. In this paper a basis for optimising some of the parameters for simple closed-die forging is proposed. Slip-line field solutions are used to predict the flow, the load and the energy in a simple two-dimensional closed-die forging operation. The influence of the design parameters; flash-land width, excess initial workpiece area and forged cross-sectional size; on complete cavity filling and efficient cavity filling are investigated. Using the latter as necessary requirements for forging, the levels of permissable design parameters are determined, the variation of these levels with the size of the cross-section then being examined.