An experimental study on foming process of heavy forging products was carried out using modeling materials. In order to verify the validity of load estimation obtained from similarity studies, comparison of load values between F.E.M. and experimental results has been made.
According to this comparison, experimentally obtained load is larger than the one obtained from F.E.M. simulation. This discrepancy might be attributed to the friction and material data used in simulation.
Based on the similarity study, open die forging is divided into several processes for Nozzle and Cup types of AISI4130 since the required forging load is lager than the machine capacity. Since the machine capacity is limited contact area between the dies and the billet is controlled at intermediate steps to reduce forming load requirement. In addition, types of forming processes were various.
Considered to reduce the possible defects into forming results, forging defects such as thinning and cracking experiments. Also, lead and plasticine were used in experiments to reduce the effect of possible materials.
Based on the developed forming sequences, the final products were formed within the machine capacity for Nozzle and Cup types of AISI 4130.
