Finite element simulation and experimental study of hot closed-die upsetting

Close-die upsetting often forms part of the sequence of producing a finished part from a billet in closed-die precision forging. Experiments have been performed to obtain the geometry of the deformed workpiece, and also the forging load as a function of punch movement during the closed-die upsetting. An elastic-plastic finite element program has also been used to simulate the process. In order to obtain realistic results from the simulation, preliminary experiments were carried out to ensure that the thermal parameters were properly introduced. The results obtained from the simulation are in good agreement with those from the experiments. As the FE simulation has been validated by experiment it may be used alone with confidence to generate data for an intelligent knowledge-based system (IKBS) for forging die design which includes similar processes.