Investigation of Die Design Influence on Required Forces in Near-Solidus Forging of Complex Components
This study investigates the influence of die design parameters on forging forces and thermomechanical responses during near-solidus forging (NSF) of complex steel components. Finite element simulations using Forge NxT analyzed six die configurations varying geometry orientation, gating system design...
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| Language: | English |
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MDPI AG
2025-07-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/9/7/245 |
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| author | John Damilola Sunday Alberto Murillo-Marrodán Eduardo García Carl Slater |
| author_facet | John Damilola Sunday Alberto Murillo-Marrodán Eduardo García Carl Slater |
| author_sort | John Damilola Sunday |
| collection | DOAJ |
| description | This study investigates the influence of die design parameters on forging forces and thermomechanical responses during near-solidus forging (NSF) of complex steel components. Finite element simulations using Forge NxT analyzed six die configurations varying geometry orientation, gating system design (conical, cylindrical, curvilinear), and draft angles (20° and 30°), with 42CrMo4E steel modeled at 1360 °C. Key responses including punch and lateral forces, temperature distribution, strain localization, and die stress were evaluated to assess design effects. Results showed that the gating system geometry critically controls material flow and load requirements. The conical gating design with a 30° draft angle yielded the lowest punch (141.54 t) and lateral (149.44 t) forces, alongside uniform temperature and strain distributions, which improve product quality by minimizing defects and incomplete filling. Lower lateral forces also reduce die opening risk, enhancing die life. In contrast, the base case with a 20° draft angle exhibited higher forces and uneven strain, increasing die stress and compromising part quality. These findings highlight the importance of selecting appropriate gating systems and draft angles to reduce forming loads, increase die life, and improve uniform material flow, contributing to better understanding of die design in NSF of complex steel components. |
| format | Article |
| id | doaj-art-2b35a57d0d5547d89d9c861e0224e6f1 |
| institution | DOAJ |
| issn | 2504-4494 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-2b35a57d0d5547d89d9c861e0224e6f12025-08-20T02:45:46ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-07-019724510.3390/jmmp9070245Investigation of Die Design Influence on Required Forces in Near-Solidus Forging of Complex ComponentsJohn Damilola Sunday0Alberto Murillo-Marrodán1Eduardo García2Carl Slater3Department of Mechanics, Design, and Industrial Management, University of Deusto, Avenida de las Universidades 24, 48007 Bilbao, SpainDepartment of Mechanics, Design, and Industrial Management, University of Deusto, Avenida de las Universidades 24, 48007 Bilbao, SpainDepartment of Mechanics, Design, and Industrial Management, University of Deusto, Avenida de las Universidades 24, 48007 Bilbao, SpainWarwick Manufacturing Group (WMG), University of Warwick, Coventry CV4 7AL, UKThis study investigates the influence of die design parameters on forging forces and thermomechanical responses during near-solidus forging (NSF) of complex steel components. Finite element simulations using Forge NxT analyzed six die configurations varying geometry orientation, gating system design (conical, cylindrical, curvilinear), and draft angles (20° and 30°), with 42CrMo4E steel modeled at 1360 °C. Key responses including punch and lateral forces, temperature distribution, strain localization, and die stress were evaluated to assess design effects. Results showed that the gating system geometry critically controls material flow and load requirements. The conical gating design with a 30° draft angle yielded the lowest punch (141.54 t) and lateral (149.44 t) forces, alongside uniform temperature and strain distributions, which improve product quality by minimizing defects and incomplete filling. Lower lateral forces also reduce die opening risk, enhancing die life. In contrast, the base case with a 20° draft angle exhibited higher forces and uneven strain, increasing die stress and compromising part quality. These findings highlight the importance of selecting appropriate gating systems and draft angles to reduce forming loads, increase die life, and improve uniform material flow, contributing to better understanding of die design in NSF of complex steel components.https://www.mdpi.com/2504-4494/9/7/245lateral forceNSFgating system designForge NxT |
| spellingShingle | John Damilola Sunday Alberto Murillo-Marrodán Eduardo García Carl Slater Investigation of Die Design Influence on Required Forces in Near-Solidus Forging of Complex Components Journal of Manufacturing and Materials Processing lateral force NSF gating system design Forge NxT |
| title | Investigation of Die Design Influence on Required Forces in Near-Solidus Forging of Complex Components |
| title_full | Investigation of Die Design Influence on Required Forces in Near-Solidus Forging of Complex Components |
| title_fullStr | Investigation of Die Design Influence on Required Forces in Near-Solidus Forging of Complex Components |
| title_full_unstemmed | Investigation of Die Design Influence on Required Forces in Near-Solidus Forging of Complex Components |
| title_short | Investigation of Die Design Influence on Required Forces in Near-Solidus Forging of Complex Components |
| title_sort | investigation of die design influence on required forces in near solidus forging of complex components |
| topic | lateral force NSF gating system design Forge NxT |
| url | https://www.mdpi.com/2504-4494/9/7/245 |
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