Experimental and Theoretical Investigation Into Rotary Forging of Axi-Symmetric Aluminium Disc

The present paper focus on the investigation into rotary forging of axi-symmetric aluminium disc experimentally and ‘Upper Bound’ theoretical analysis. Conical die with include angle of 1700 , i.e. skew angle of 50 was fabricated and experiments were performed using these dies on radial drilling machine. The deformation and conical indented contact area were critically investigated. The theoretical analysis was done based on ‘Upper Bound’ approach, where exponential velocity field and corresponding strain rates satisfying necessary boundary conditions were proposed. Using these expressions, total energy expended during rotary forging was computed, which was used to compute the average rotary forging load. For ease of computation mechanics, the entire rotary forging process was considered into two phases, i.e., indentation phase and rotary phase. The final average rotary forging load was computed by summing up the average loads during indentation and rotary phases. The effect of various rotary forging characteristics like axial feed rate, rotational speed, skew angle on percent deformation, average forging load etc were studied. It is expected that present work will be useful for the prediction of the rotary forging load, as well for the design of rotary forging processes.