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<p>In metal forging, Computer-Aided Design (CAD) and Computer-Aided Engineering (CAE) are essential for creating accurate digital models and conducting numerical simulations aimed at improving product performance and quality, as well as reducing material waste. This work investigates the feasibility of forging axisymmetric weld neck flanges without folds in a single step using closed dies with flash. Currently, these components are forged in multiple steps, which increase production costs. CAD and CAE, coupled with Finite Element Method (FEM) simulations, are employed to understand the mechanisms associated with the formation of folding defects. Traditionally, such defects are addressed through non-critical adjustments and trial and error, such as increasing billet volume to convey defects toward the flash gutter. Analytical methods are limited due to the dynamic complexity of material flow and frictional effects during forging. This study highlights the applicability of CAD/CAE to analyze and eliminate folding defects in industrially forged weld neck flanges. Numerical simulations demonstrate that altering the radii of the upper die and tilting specific areas where folding typically occurs effectively eliminate these defects. These modifications alter the material flow during upsetting and spreading, preventing the formation of folds. Additionally, the macrographic analysis detects potential folds in specific regions, guiding the evaluation of the upper die and billet geometries. Following numerical analysis and adjustments, a new upper die geometry is proposed, integrating CAD-based geometric modifications and near net shape techniques. Upon numerical confirmation of the folding defect elimination, an enhanced upper die is industrially produced to validate the numerical, allowing the forging of a new weld neck flange in a single step model. This approach highlights the importance of numerical simulations in advanced manufacturing processes and product design, significantly enhancing the quality and efficiency of forged components in industrial sectors such as aerospace, automotive, and petrochemical industries.</p>

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Suppression of weld neck flange folding in single step forging

  • 期刊论文

  • 发表日期：

    2025年2月22日

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  • Pedro Henrique Degasperi Escolastico,
  • Augusto Moura Martins,
  • Diogo Azevedo de Oliveira,
  • Alexandre Mendes Abrão,
  • Frederico de Castro Magalhães

摘要

In metal forging, Computer-Aided Design (CAD) and Computer-Aided Engineering (CAE) are essential for creating accurate digital models and conducting numerical simulations aimed at improving product performance and quality, as well as reducing material waste. This work investigates the feasibility of forging axisymmetric weld neck flanges without folds in a single step using closed dies with flash. Currently, these components are forged in multiple steps, which increase production costs. CAD and CAE, coupled with Finite Element Method (FEM) simulations, are employed to understand the mechanisms associated with the formation of folding defects. Traditionally, such defects are addressed through non-critical adjustments and trial and error, such as increasing billet volume to convey defects toward the flash gutter. Analytical methods are limited due to the dynamic complexity of material flow and frictional effects during forging. This study highlights the applicability of CAD/CAE to analyze and eliminate folding defects in industrially forged weld neck flanges. Numerical simulations demonstrate that altering the radii of the upper die and tilting specific areas where folding typically occurs effectively eliminate these defects. These modifications alter the material flow during upsetting and spreading, preventing the formation of folds. Additionally, the macrographic analysis detects potential folds in specific regions, guiding the evaluation of the upper die and billet geometries. Following numerical analysis and adjustments, a new upper die geometry is proposed, integrating CAD-based geometric modifications and near net shape techniques. Upon numerical confirmation of the folding defect elimination, an enhanced upper die is industrially produced to validate the numerical, allowing the forging of a new weld neck flange in a single step model. This approach highlights the importance of numerical simulations in advanced manufacturing processes and product design, significantly enhancing the quality and efficiency of forged components in industrial sectors such as aerospace, automotive, and petrochemical industries.