Simulation of temperature distribution in forging of a workpiece with a single asperity

ABSTRACT

Temperature distribution in a forging process influences the lubricant behaviour and die-wear. Non-uniform temperature distribution at the die-work interface results in the breakdown of lubrication film, which increases the heat generation due to increased friction. This work investigates the temperature distribution in the forging of a workpiece with a single asperity using the finite element (FE) simulations. Effects of asperity height in relation to workpiece, friction at die-work interface, percentage reduction and die velocity are studied. During the forging process, the temperature developed at the asperity region rises very rapidly. The asperity attains the maximum temperature after attaining its full height deformation. For the same deformation of workpiece, the temperature at asperity increases with an increase in the asperity height. The temperature at the asperity reduces with an increase in the friction at the die-work interface. The temperature at asperity as well as on the whole workpiece increases with increasing reduction. As heat dissipation from the workpiece surface is more at a relatively lower speed, the maximum temperature developed at asperity is greater at a higher speed. Insight provided by these simulations will assist in understanding the tribology of metal forming.

KEYWORDS:

• Temperature
• asperity
• finite element modelling
• cold forging
• friction
• deformation

Acknowledgements

Authors wish to acknowledge the two funding agencies—Russian Foundation for Basic Research (RFBR) and Department of Science and Technology (DST), New Delhi, for sponsoring the Indo-Russian Project entitled “Experimental and numerical research on contact friction in the process of plastic deformation by means of compression with torsion”. The grant numbers are 19-58-45020 and INT/RUS/RFBR/388, respectively.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Funding

The work was supported by the Russian Foundation for Basic Research [19-58-45020]; Department of Science and Technology, New Delhi [INT/RUS/RFBR/388]