Deformation characteristics and mechanisms of the cold rotary forging of a ring workpiece

Cold rotary forging is an advanced but very complex incremental metal plastic-forming technology under coupled effects with multifactors. Previous research concentrates mainly on the study of the cold rotary forging process of a cylindrical workpiece and thus it is essential to explore the deformation characteristics and mechanisms of the cold rotary forging of a ring workpiece in order to use rotary forging presses with maximum efficiency. In the current paper, numerous simulations have been carried out based on a valid three-dimensional elastic-plastic dynamic explicit finite element model developed using ABAQUS software. Through these simulations, the interactive effects of three main processing parameters, the feed rate v of the lower die, rotational speed n, and inclination angle gamma of the upper die on the cold rotary forging process of a ring workpiece, have been thoroughly explored. Furthermore, a comprehensive and decisive factor in cold rotary forging, namely the equivalent feed amount per revolution Q, is put forward, and its effects on the forming process have also been thoroughly revealed. The results obtained are explained with regard to the plastic penetrating states of the deformed ring workpiece. The results of this research thoroughly reveal the deformation characteristics and mechanisms of cold rotary forging of a ring workpiece, and provide valuable guidelines for optimizing the processing parameters so as to control precisely the cold rotary forging process of a ring workpiece.