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 separately 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-disc type components by the flat-die thermal differential forging process is conducted. The results show that: (i) the achievement of the anticipated profiles requires the suitable control of large temperature gradients in the billet; (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 billet significantly influence the metal flow in high speed forging; (iv) the metal flow in low speed forging is affected by both the temperature distributions and the condition of continuous in situ heating. © 2001 Elsevier Science B.V.