Rational parameters of profiled workpieces for an upsetting process

An upsetting process of specially profiled workpieces was proposed. Modeling of a workpiece upsetting, profiled as a cylinder with conical and cylindrical ledges was done using a finite element method. During the upsetting of these workpieces, buckling occurs. Schemes of upsetting a workpiece with conical ledges result in a decrease in the irregularity of the equivalent strain distribution in the longitudinal section. This scheme produces a zone of minimal equivalent strain decrease in the workpiece. It was found that during the upsetting process of the workpiece with a conical ledge on the lateral surface and in the center, compressive stresses appear. These stresses contribute to the closure of voids in an ingot during the upsetting process. Rational workpiece parameters were found which allow the production of forgings with minimal irregularity of equivalent strain distribution, minimal formation of a barrel, and a favorable stress state in the workpiece. Experimental research, which confirms the advantages of upsetting specially profiled workpieces, was done.