Comparison of various preforms for hot forging of bearing rings

Production of bearing rings by hot forging is investigated in this study. The aim of the study is to determine a feasible preform at the first station of the forming process such that the tool wear is prolonged and tool fracture is prevented. For this purpose, it is assumed that the contact pressure at the interface between tools and workpiece is the predominant process parameter. The contact pressures are determined by precise thermo-mechanical coupled finite element analyses based on elastic–plastic material description. Material flow curves for various temperatures and strain-rates are determined in velocity controlled upsetting tests. Cooling experiments are used to determine the heat transfer coefficients. Accuracy of the numerical models has been verified by extensive numerical convergence studies and finally by comparing with experimental measurements. The analysed preforms are evaluated using a scheme of weight-factors for the various tool parts. Finally, a preform is suggested for which the weighted total tool pressure could be reduced by 15%.