On the effect of deformation conditions on the metal flow behavior during upsetting process using finite element simulation DEFORM 3D software

Abstract The study reports on the metal flow behaviour during upsetting or forging using the finite element method. Forging simulation studied the metal flow behaviour of a laboratory-sized specimen and a cylindrical engine connecting rod specimen of AISI 52100 high-chromium steel specified in the software database. The focus was to study the effect of deformation conditions (temperature and die velocity) on metal flow behaviour during forging. The simulation results showed heterogeneous metal flow behaviour during forging. Hence, this indicates that effective flow stress and flow strain, particle flow velocity, effective strain rate, damage and temperature distribution exhibited inhomogeneous deformation behaviour. As the temperature increased, the forging load decreased, thus a decrease in deformation resistance. The simulation of the engine connecting rod further confirmed inhomogeneous deformation during forging. Damage coefficient results show that the crack pin end had a higher damage probability during forging. This study clearly showed that finite element simulation can predict metal flow behaviour during the forging of AISI 52100 steel. The study output provides a basis for analysing and optimising most industrial metal forming processes using a numerical simulation approach. Hence, this method is effective in predicting flow behaviour.