Optimization of open die forging of round shapes using FEM analysis

A three-dimensional rigid-plastic finite element method (FEM) analysis has been performed to optimize an open die forging process in the production of circular shapes (i.e. round bars, spindles, rotors, etc.). In producing circular shapes by open die forging, it is difficult to achieve the optimal set of process parameters by trial and error within an industrial environment. In this study, the finite element method was used to analyze the practice of open die forging, focusing on the effects of feed rate and rotation angle for optimal forging pass design. The optimal combination of feed rate and rotation angle has been determined by quantifying the radius profile in the longitudinal direction and roundness of the product. From an analysis of the results, optimal process conditions are proposed for the production of circular shapes with good dimensional accuracy by open die forging.