FEM simulation of the flat-die preform forging of steel shaft-disc type components by thermal differential heating

The manufacturing of shaft-disc type components by the assembling of separa tely produced shafts and discs together is rather time consuming and costly . The application of the flat-die thermal differential forging process can produce the preform shape for this type of component, Using coupled thermal -viscoplastic FEM, a simulation study for the preforming of steel shaft-dis c type components by the flat-die thermal differential forging process is c onducted. The results show that: (i) the achievement of the anticipated pro files requires the suitable-control of large temperature gradients in the b illet; (ii) the desirable large temperature gradients can be obtained by a suitable combination of heat capacitors and the assignment of power; (iii) the temperature distributions in a biller significantly influence the metal flow in high speed forging; (iv) the metal flow in low speed forging is af fected by both the temperature distributions and the condition of continuou s in situ heating. (C) 2001 Elsevier Science B.V. All rights reserved.