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Abstract
A resistance heating method and a one-step-gradual forging process were used to study a billet within a die. The billet was directly heated accompanied with a progressive heating manner. The pressing speed of the upper die is kept at the same course with the billet heating speed, thus integrating the forming procedure by simply controlling one speed in effect. Experimentally, it is found that based on this innovative forming method, the experimental results indicated that the billet can be heated to 1000°C from top to bottom within approximately 5 s. This leads to a further modification of the material flow for a 12-point bolt-head, which in the end results in an improvement of the forming ability. Most importantly, the forming load of gradually forging can cause a 25% deduction compared with the one performed by one-step forging. Numerically, the commercial finite element method package of DEFORM was used to simulate the novel one-step-gradual forging process. The simulated material flow phenomena were thoroughly studied in subsequence. The results between FEM simulations and experiments showed good agreements.