Comparative Analysis of Material Flow Stress in Mid-Carbon Steel (S45C) Utilizing the Zener-Hollomon Equation and Finite Element Method

This study investigates the hot forging process of S45C carbon steel, a commonly used alloy. The process involves heating the workpiece above its recrystallization point to enhance flexibility, followed by compressive deformation. The study compares the methodology for determining Zener-Hollomon parameters using experimental data analysis and default simulation software parameters. Compressive tests at strain rates of 0.1–10 s−1 and temperatures 900–1200 °C are conducted. The results show that parameters obtained from compressive testing are significantly more accurate than default software parameters, with only a 2.87% error compared to the software default parameters errors, which is as high as 35.05% for the Preforming Process and 3.40% and 31.41% for the Finishing process. This underscores the importance of accurate material data in simulations for hot forging processes and offers valuable insights for improving precision, efficiency, and cost-effectiveness in hot forging operations.