A computer package for simulation and analysis of rotary forging
This thesis presents the development of a software package to simulate and graphically represent the tool/workpiece kinematics in rotary forging. A hypothetical workpiece of non-constant volume is always used. Share changes are achieved by a process of material removal, analogous to metal cutting. Using a quantitative approach, the software is shown to be capable of calculating the tool/workpiece instantaneous contact zone and the volume of material being removed. The software has been developed and used to produce an analysis of radially configurated conic tools. This is believed to be a unique approach to the simulation of the rotary forging process. Various types of rotary forging machines can be identified by the motion of the conic tool and the hypothetical workpiece. A mathematical/ geometrical model is developed which can be used to simulate all possible rotary forging die motions. The model is used to determine the position in space of any point on the die, regardless of its motion and geometry. The software development has been used to graphically simulate the loci of points on a die, during movement of the die. The mathematical model is used to simulate a non-constant volume workpiece consisting of a large number of concentric cylinders of specified height and radius, with infinitesimal thickness. The interaction between tool and workpiece is achieved by using a method of geometric comparison. This allows an assessment of changes in the shape of the workpiece. Extension of the program, using a generated mesh, results in a numerical analysis of the rotary forging process. The data generated from the simulation phase, incorporating some previously developed software, is used to calculate the instantaneous area of contact and the volume of material being removed. Radially configurated tooling is achieved by the introduction of a database, into the software package. Guidelines are established for the practical design of radially configurated tools. The ability of the program to interact radially configurated tools with non-constant volume workpieces, is graphically/numerically investigated. The developed program could offer many potential applications in areas such as: the calculation of forming loads and stresses, pressure distribution, etc. Further, the program can establish some basic boundary conditions; which are essential information for the development of any finite element package for predicting metal flow in rotary forging.