OPTIMIZATION OF DEFECT PREVENTION IN HOT FORGING OF CuZn40Pb2 BRASS ALLOY WATER VALVE COVERS: A FINITE ELEMENT AND EXPERIMENTAL APPROACH

This study explores the hot forging process of CuZn40Pb2 brass alloy water valve covers through a combination of finite element modeling and experimental trials. Key factors influencing defect formation, such as the cylindrical workpiece geometry and die temperature, are examined in detail. Simulations using Deform 3D software focused on the impact of temperature on material flow behavior, incorporating inputs such as geometry, filling sequence, and applied force. Experimental findings underscored the crucial role of the friction coefficient, which diminishes with the use of lubricants, in controlling material flow. The reduction in friction, caused by heat generated from die friction during forging, was found to elevate the risk of defects. Stress and strain analysis from the simulations revealed a complex interaction between temperature and friction, significantly affecting defect formation. The strong correlation between simulation and experimental results confirmed the value of computational modeling in predicting and preventing defects. This research provides valuable insights into optimizing hot forging parameters for CuZn40Pb2 brass alloy components, enabling improvements in product quality and process efficiency.