Design of multistage forging processes by numerical simulation and experimental verification

Abstract The Variety of components with different shapes & Sizes with different materials can be formed using Multi stage hot forging processes. In previous times, forging process in multi stage was designed on basis of experience gained in the previous forging practices. Nowadays, many software packages based on FE (finite elements) and FV (finite volumes) method are developed. This enables creation of forging process in more effective and accurate condition. The paper insight is given in the design of multi stage hot forging process for a critical geometry of Socket Forging in a multi-step forging process. The main criterion is to minimize the number of forging stages, proper filling and stressing of the dies by analysing the contact pressure. The Theoretical derivation & Numerical Simulation results are verified with practical, industrial environment.