FEM simulation of the flat-die preform forging of steel shaft–disc type components by thermal differential heating

The manufacturing of shaft–disc type components by the assembling of separately produced shafts and discs together is rather time consuming and costly. The application of the flat-die thermal differential forging process can produce the preform shape for this type of component. Using coupled thermal-viscoplastic FEM, a simulation study for the preforming of steel shaft–disc type components by the flat-die thermal differential forging process is conducted. The results show that: (i) the achievement of the anticipated profiles requires the suitable control of large temperature gradients in the billet; (ii) the desirable large temperature gradients can be obtained by a suitable combination of heat capacitors and the assignment of power; (iii) the temperature distributions in a billet significantly influence the metal flow in high speed forging; (iv) the metal flow in low speed forging is affected by both the temperature distributions and the condition of continuous in situ heating.