A Study on Formation Process of Secondary Upsetting Defect in Electric Upsetting and Optimization of Processing Parameters Based on Multi-Field Coupling FEM


Mat. Res.




The electric upsetting process is an excellent electrically assisted preforming technique with electrical-thermal-mechanical multi-field coupling characteristic. The secondary upsetting defect in electric upsetting with inappropriate parameters combinations could result in folds in subsequent forging process. In order to analyze the formation process of the secondary upsetting defect, the finite element model of electric upsetting was constructed based on the multi-field coupling solver platform, MSC.Marc. It is concluded through the numerical simulation with inappropriate parameters combination that the main factor causing the secondary upsetting defect is the large temperature decrease of the deformed portion after the formation of drum-shape in the preliminary stage of electric upsetting. Subsequently, the secondary upsetting defect has been successfully avoided via a three-stage current mode. Finally, a novel optimization method based on close-cycle control of current in numerical simulation was established by developing a current subroutine in MSC.Marc, which was proved to be effective for the elimination of the secondary upsetting defect.

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