3D FE modeling simulation of cold rotary forging of a cylinder workpiece

Cold rotary forging is an advanced but much complex incremental metal forming process with multi-factors coupling interactive effects. Because of the limit of the experimental and analytical methods, many problems such as deformation mechanism, effects of processing parameters on the cold rotary forging process and so on need to be solved through an overall and detailed analysis with the FE modeling method. In the current work, a reasonable 3D elastic–plastic dynamic explicit FE model of cold rotary forging of a cylinder workpiece is established under the ABAQUS software environment. Based on the valid 3D FE model, the effect laws of three main processing parameters, feed rate v of the lower die, rotational speed n and inclination angle γ of the upper die on metal flow, the degree of inhomogeneous deformation of workpiece and force and power parameters in the cold rotary forging process have been explored.