Efficient forging process to improve the closing effect of the inner void on an ultra-large ingot

The internal state of an ingot structure manufactured by the casting process has many loose structures. Generally, loose ingot structures make it difficult to obtain sound material properties. Unsound factors such as voids, porosity and shrinkage in the ingot can be improved by the forging process. The closing of the internal voids depends on the forging process. In this study, numerical analysis was carried out to find the upsetting and cogging processes increasing the internal forging effect of an ultra-large ingot (520 tons). Various parameters such as the ratio of height to diameter of ingot, shifting method, die staggering, and pressing depth were investigated. In addition, verification tests were performed visually using a 1/25 scale model test with pure lead. Results from the numerical analysis and the scaled-down model experiment were compared. The optimal forging process was applied to manufacture a mock-up product. An efficient forging process was suggested to improve the void closing and to achieve the uniform forging effect in the upsetting and cogging process of an ultra-large ingot.