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Thermal Management in Multi-Stage Hot Forging: Computational Advances in Contact and Spray-Cooling Modelling.

Gonzalo Veiga-Piñeiro1, Elena Martin-Ortega1, Salvador Pérez-Betanzos2

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Precise thermal management in hot forging is key to minimizing defects. This study developed a validated thermal analysis framework for the complete forging cycle, improving die performance and part quality.

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Area of Science:

  • Mechanical Engineering
  • Materials Science
  • Manufacturing Processes

Background:

  • Hot forging innovations like floating dies require precise control of die geometry distortions.
  • Thermal gradients are the primary cause of these distortions, impacting production efficiency and part quality.

Purpose of the Study:

  • To introduce a comprehensive thermal analysis framework for the complete hot forging cycle.
  • To develop and implement advanced heat transfer models for accurate thermal behavior evaluation of dies.

Main Methods:

  • Developed a pressure- and lubrication-dependent contact heat transfer model.
  • Created a spray-cooling model simulating fluid dispersion on die surfaces.
  • Implemented models in FORGE-NxT software and validated with industrial thermal imaging data.

Main Results:

  • The developed framework accurately simulates the complete forging cycle, including billet transfer, forging, spray-cooling, and lubrication.
  • Validated simulation results showed an average temperature deviation of only 5.8% compared to industrial data.
  • The approach provides a reliable estimation of thermal fields within dies.

Conclusions:

  • The validated thermal analysis framework is a practical tool for optimizing hot forging processes.
  • It enables reduction of burr formation and extension of die life through accurate thermal field estimation.
  • The methodology is adaptable to various hot forging applications demanding critical thermal control for quality and efficiency.