To eliminate the defects during piston skirt isothermal forming process,simulations under different process parameters such as the deformation temperature and friction factor were analyzed with the rigid-plastic FEA.Deformation pattern,metal flow and influence of process parameters were concluded.The prediction load value with a relative error of 4.98% is more accurate to the testing one than that from the empirical formula whose relative error is up to 50.8%.Finally,based on the simulation results,an improved process at 300 ℃ and 0.005-0.05 s-1 was verified without any defects by the physical try-out.
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