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Radial forging and indentation forging processes are two processes used for sizing and/or internal profiling of tubes. In this paper, the two processes are simulated using finite element method and their results are compared with Experimental results. The purpose of this paper is to compare the pattern of residual stresses in both processes. Copyright © 2005 SAE International  

Radial forging is an open forging process used for reducing the diameters of shafts, tubes, stepped shafts and axels, as well as for creating internal profiles for tubes such as rifling the gun barrels. The radial forging of tubes is usually performed over a mandrel to create an internal profile and/or size the internal diameter; but the process can also be used without a mandrel when workpiece geometry does not allow it or the internal surface quality is not critical. In some industrial applications, it may not be possible to use a mandrel inside the tubular workpiece, e.g., due to geometrical limitations of the workpiece. In this study, finite element modelling is applied to model the... 

In this work, a comprehensive study of radial forging process is presented through 2-D axisymmetric and 3-D finite element simulations while considering internal tube profile. The tube used in this investigation has four internal helical grooves along its length. The material is modeled with the elastic-plastic behavior, and sliding-sticking friction model is utilized to model the die-workpiece and mandrel-workpiece contacts. The numerical results in the 2-D case are compared with available experimental data. Residual stresses in the forged product, stress concentration around the grooves, pressure distribution on the hammers and mandrel and maximum forging load are studied. The effects of... 

Some mechanical and metallurgical properties of hollow and solid long forged products are compared. The metallurgical properties include such micro- and macro-structural characteristics as the grain size and grain flow patterns. Mechanical evaluation was performed by means of hardness testing. Some theoretical analyses were also carried out. The results indicate that the hollow or mandrel forged products possess better properties. Both the mechanical and metallurgical properties are more uniform and homogeneous through the thickness direction in such products. By contrast, in the solid forged parts, there is a gradient in the micro- and macro-structural properties from the surface to the... 

Radial forging is an open die forging process used for reducing the diameters of shafts, tubes, stepped shafts and axels, and for creating internal profiles in tubes. Among parameters affecting process variables, the die geometry is of fundamental importance and greatly influences variables such as forging load, stress distribution on the dies, metal flow during deformation, and surface finish of the forged product. In this paper a generalized slab method analysis of radial forging process is presented which can handle this process with curved shape dies. Results for dies with various curves are presented and it is shown that the analysis reduces to that of Lahoti and Altan [2] when the die... 

Radial forging is an open forging process used for reducing the diameters of shafts, tubes, stepped shafts and axels, and creating internal profiles for tubes such as rifling of gun barrels. Usually a mandrel is used inside a tubular workpiece to create internal profile and/or size the internal diameter, but the process can also be performed without a mandrel when workpiece geometry does not allow utilizing it or the internal surface quality is not critical. Moreover, in stepped shafts and tubes, often there is a fillet connecting two different sections. If it is possible to produce that fillet during the forging process, the process could be more cost effective. So, in this paper, four... 

Radial forging is an open die forging process used for reducing the diameter of shafts, tubes and axels. In the present research, a new velocity field was developed to analyze the radial forging process by the upper bound method. The forging load was predicted by minimizing the deformation power with regards to the location of neutral plane. The accuracy of the model was verified by comparing the predicted forging loads with experimental results published by the previous researcher. A good agreement was found between the two sets of results. © 2007 Elsevier B.V. All rights reserved  

Radial forging is an open die forging process used for reducing diameter of shafts, tubes, stepped shafts and axels, and creating the internal profiles for tubes such as rifling the gun barrels. In the present research, a new model based on calculating the deformation work was developed to find an upper bound limit for the deformation load in the case of radial forging of rods and tubes. Also, the model was used to assess the effects of the process parameters. The accuracy of the model was tested by comparing the predicted results with those achieved from the experiment at work of Uhlig [Investigation of the motions and the forces in radial swaging. Doctoral Dissertation, Technical... 

Radial forging is an open die forging process used for reducing the diameters of shafts, tubes, stepped shafts and axles, and for creating internal profiles in tubes. Due to very large forging loads, the tool should withstand high stress and wear. Therefore, the success of the forging process depends upon recognition of the die failure factors and optimization of the tool working conditions that enhance tool life. In this study, the effect of process parameters on tool life in the cold radial forging process is investigated using nonlinear three dimensional finite element modeling. Wear and mechanical fatigue are considered as the main modes of tool failure, and a parametric study on the... 

Radial forging is an open die forging process used for reducing the diameters of shafts, tubes, stepped shafts and axels, and for creating internal profiles in tubes. In this study, the effect of the workpiece rotation (the circumferential feed) on the strain and residual stress distribution in the inner surface of the tube in the cold radial forging process is investigated using nonlinear three dimensional finite element modeling. To verify the model, the predicted radial forging load is compared with the published experimental data which shows a good agreement. It is shown that for achieving a more favorable residual stress distribution in the workpiece inner surface, the rotation angle... 

Utilizing the Finite Element Method (FEM), the strain field in the radial forging process of tube is calculated at different process conditions and compared with the experimental results achieved using the microhardness test. The effect of various process parameters such as friction, axial feed, back push and front pull forces and die angles on the strain field are investigated. Using the results of the analysis, it is shown that the deformation inhomogeneity, introduced by an Inhomogeneity Factor (IF), is maximum in the inner zone of tube, while the minimum and the maximum effective strains are appeared at the inner zone of tube and about the core of the tube thickness, respectively. Also,... 

In this study, the artificial neural network (ANN) and the Taguchi method are employed to optimize the radial force and strain inhomogeneity in radial forging process. The finite element analysis of the process verified by the microhardness test (to confirm the predicted strain distribution) and the experimental forging load published by the previous researcher are used to predict the strain distribution in the final product and the radial force. At first, a combination of process parameters are selected by orthogonal array for numerical experimenting by Taguchi method and then simulated by FEM. Then the optimum conditions are predicted via the Taguchi method. After that, by using the FEM... 

Radial forging is one of the modern open die forging techniques and has a wide application in producing machine parts. During operation at high temperatures, severe temperature change associated with mechanical loads and the resultant wearing of the die surface lead to intense variation in strain on the die surface. Therefore, under this operating condition, thermo-mechanical fatigue (TMF) occurs on the surface of the radial forging die. TMF decreases the life of the die severely. In the present research, different layers were deposited on a 1.2714 steel die by SMAW and GTAW, with a weld wire of UDIMET 520. The microstructure of the radial forging die surface was investigated during welding...