Computerized design and modeling of Forging Process of Large Parts

A stress-strain state and a resize of an axial defect during upsetting of large forgings have been investigated in the article. Theoretical research based on a finite element method has been conducted. The upsetting of cylindrical steel workpieces which had the axial defect equal to 10 % of the workpiece diameter has been simulated. Upsetting has been carried out by flat plates (solid and with hole). The result of the studies showed that the main influence on the workpiece shape and stress-strain state of the workpiece metal have ratio of blanks dimensions. Upsetting by flat plates does not provide the closure of axial defects. The hole in the plates increases the non-uniformity of strain distribution and also does not provide the axial defects closure. The new technological process of plate forging, which allows to lower the cost price of their manufacture and to increase quality of forged pieces due welding of a defect axial zone at the expense of localization of major squeezing stress and double alternating-sign curving of the workpiece here was designed.