Numerical and experimental investigations on the extension of friction and heat transfer models for an improved simulation of hot forging processes

In hot forging processes the complex heat transfer and friction conditions are significantly influenced by the local effects occurring at the contact interface between the tool and workpiece. These effects basically include the prevailing normal stress and shear yield stress of the workpiece material, the temperature and surface roughness of the tool and workpiece as well as the relative sliding velocity. Hence, these effects were considered for the extension of the heat transfer and friction models. Two representative forging tests were carried out; the forming load and surface temperature distribution were recorded. By means of this data, the models were appropriately extended and adjusted using the software FORGE ®. The application of the extended models allows for a more accurate description of the interaction at the contact interface. Thus FE computations of hot forging processes deliver more realistic results.