Virtual Labs

Tools

Upsetting Process: An Overview

Variables in Upset Forging Process

EFFECT OF FORGING EQUIPMENT ON FORGING PROCESS

Each forging press or machine (mechanical, hydraulic, screw, hammer) has unique stroke characteristics.
One important variable that affects the forming process is press ram speed.

Hydraulic Press → constant ram speed
Mechanical Press → variable ram speed

HYDRAULIC PRESS SIMULATION

Variable	Value
Material	AlZn5.6Mg2.5Cu1.5
Height	100 mm
Diameter	100 mm
Billet Temperature	300°C
Die Temperature	250°C
% Reduction in Height	50%
Press	Hydraulic

Simulation Video

FORCE DURING UPSETTING PROCESS (Hydraulic)

Material	CK45
Height	100 mm
Diameter	100 mm
Billet Temperature	1050°C
Die Temperature	250°C
% Reduction	50%
Press	Hydraulic

Material	Ti6Alv4
Height	100 mm
Diameter	100 mm
Billet Temperature	1200°C
Die Temperature	250°C
% Reduction	50%
Press	Hydraulic

Material	CuZn40Al2
Height	100 mm
Diameter	100 mm
Billet Temperature	650°C
Die Temperature	250°C
% Reduction	50%
Press	Hydraulic

MECHANICAL PRESS SIMULATION

Variable	Value
Material	AlZn5.6Mg2.5Cu1.5
Height	100 mm
Diameter	100 mm
Billet Temperature	300°C
Die Temperature	250°C
% Reduction	50%
Press	Mechanical

FORCE DURING UPSETTING PROCESS (Mechanical)

Material	CK45
Height	100 mm
Diameter	100 mm
Billet Temperature	1050°C
Die Temperature	250°C
% Reduction	50%
Press	Mechanical

Material	Ti6Alv4
Height	100 mm
Diameter	100 mm
Billet Temperature	1200°C
Die Temperature	250°C
% Reduction	50%
Press	Mechanical

Material	CuZn40Al2
Height	100 mm
Diameter	100 mm
Billet Temperature	650°C
Die Temperature	250°C
% Reduction	50%
Press	Mechanical

HAMMER PRESS SIMULATION

Variable	Value
Material	AlZn5.6Mg2.5Cu1.5
Height	100 mm
Diameter	100 mm
Billet Temperature	300°C
Die Temperature	250°C
% Reduction	50%
Press	Hammer

FORCE DURING UPSETTING PROCESS (Hammer)

Material	CK45
Height	100 mm
Diameter	100 mm
Billet Temperature	1050°C
Die Temperature	250°C
% Reduction	50%
Press	Hammer

Material	Ti6Alv4
Height	100 mm
Diameter	100 mm
Billet Temperature	1200°C
Die Temperature	250°C
% Reduction	50%
Press	Hammer

Material	CuZn40Al2
Height	100 mm
Diameter	100 mm
Billet Temperature	650°C
Die Temperature	250°C
% Reduction	50%
Press	Hammer

COMPARISON VIDEO