Study on Load Control and Optimization of Rotary Forging Method for Heavy and Thick-walled Container Head by FEM

摘要

In this study, the finite element method (FEM) was used to simulate the rotary forging process of a heavy and thick-walled container head, and the problems about load, strain distribution and optimization of rotary forging method were studied. First, five controlling factors of load were defined, which were single reduction amount (δ), reduction rate (ν), thickness of top die (ω), rotary angle (θ) and rotary way (γ) respectively, and their influence degree on load was studied later. Then the influence of y on strain distribution was investigated. The results indicate δ, ν and ω have a strong influence on load, while θ and γ have a small influence on it; the strain distribution under crossed rotary way which is proposed in this paper is more homogeneous than stepwise rotary way. Based on the research results, a new multi-stage rotary forging method was proposed, by which load and strain distribution could be controlled effectively by means of an optimized combination of the five controlling factors in different forming stages. The simulation results are in good agreement with practical production. This study can provide valuable guidance in load control and process optimization for other similar heavy blind-hole forgings.