Three‐dimensional finite element analysis of open‐die forging

Abstract

Abstract Three‐dimensional finite element analysis is applied to operation sequences in open‐die forging. Flat tools with rounded edges for open‐die forging are geometrically modelled using Bézier curves. With this technique, the problems at the die‐workpiece interface, such as the integration of frictional stress, node touching on dies and node separating from dies, can be handled effectively. It is shown that in solving general symmetric problems computation time can be saved by reducing variables and rearranging them in the stiffness matrix. One‐bite operations and operation sequences for producing two‐size bars and two‐size pipes in several bites are investigated in regard to geometry, load, energy and deformation distribution.