International Journal of Emerging Technology and Advanced Engineering

There are a wide range of physical defects which occur during metal forming processes. These defects, which may occur on the surface or be internal, are undesirable not only because of the surface appearance, but because they may adversely affect the strength, formability and other manufacturing characteristics of the material. Some physical defects in metal forming processes such as rolling and forging, Defects in forging reduce its strength. Appreciable residual stresses and warping can occur on the quenching of steel forgings in heat treatment. They occur for a number of reasons including faults in original metal, incorrect die design, improper heating and lubrication. Defects of forged product include exterior cracking, interior cracking, laps, cold shuts, warping of the part, improperly formed sections and dead zones. In this project we will analysis the metal of forging and try to reduce metal defects in forging processes. Finite element analysis is used to predict residual stresses in forgings .The objective of this project is to obtain an optimal billet shape in the consideration of the metal flow deformation in closed die forging process. Finite element method in conjunction with optimization algorithm was used to analyze the effect of billet shape on forging load in axisymmetric closed for die forging process. ANSYS was used to simulate closed die forging process and then performing a series of optimization iteration in order to obtain the optimal shape of the billet based on forging load minimization. The material used is aluminum metal matrix composite (ALMgSi matrix with 10% SiC particles). The goal of the simulation and optimization process is to minimize the forging load and produce crack-free forgings. The optimal shape of the billet that gives minimum forging load was obtained after several optimization iterations. The approach used in this study could be extended to the optimization of more complicated forging product. Due to the advances in computer technology based finite element software, the forging load can be easily estimated which is iterative process in the old technique of prototype built up and destructive testing. In the present work consideration 3 critical design parameters with critical plastic strain limit as the state variable and keeping the forging load as the objective function and the billet shape is optimized for different diameter to height. Keywords-Die Forging, Finite Element Method, Metal Matrix Composites, Optimization , induction forging, finite element analysis, residual stresses in forging.