A parametric study on residual stresses and forging load in cold radial forging process

In this work, a comprehensive study of radial forging process is presented through 2-D axisymmetric and 3-D finite element simulations while considering internal tube profile. The tube used in this investigation has four internal helical grooves along its length. The material is modeled with the elastic-plastic behavior, and sliding-sticking friction model is utilized to model the die-workpiece and mandrel-workpiece contacts. The numerical results in the 2-D case are compared with available experimental data. Residual stresses in the forged product, stress concentration around the grooves, pressure distribution on the hammers and mandrel and maximum forging load are studied. The effects of process parameters such as workpiece and die geometries, percentage of deformation, and workpiece motions on residual stresses and applied pressures on the hammers and mandrel are investigated. The results provide a valuable insight into the parameters affecting radially forged products and provide a useful tool for better design of this process.