Modular Analysis of Geometry and Stresses in Closed-Die Forging: Application to a Structural Part

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Abstract
A computerized modular method is developed for predicting shape complexity, material volume, load, stress distributions, and center of loading in forgings. The method consists of dividing a forging into standard components which can be assembled in a building-block manner to analyze a given forging. The method has been applied to a nonsymmetric rib-and-web-type aircraft part from 6061 aluminum. The flow stress during forging, in two distinct zones of the part, was calculated by estimating average forging temperatures. The predicted values of the forging variables are compared with experimental results. The predicted forging load, which varies with the tool-material interface friction, agreed well with the measured load for a friction factor of about 0.3.

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