Optimization of Hot Forging Process Parameters of Alloy CuZn40Pb2 Using an Experimental and Numerical Approach

Area of Science:

• Materials Science and Engineering
• Manufacturing Processes

Background:

• Hot forging is vital for enhancing mechanical properties of alloys like CuZn40Pb2.
• Process parameter optimization is key to preventing damage and ensuring product quality.

Purpose of the Study:

• To optimize hot forging parameters (temperature, speed) for CuZn40Pb2 brass.
• To integrate experimental and numerical simulation methods for process enhancement.
• To identify conditions that minimize damage during forging.

Main Methods:

• Experimental forging tests using a mechanical press.
• Numerical simulations employing FORGE FE software and the Hensel-Spittel constitutive model.
• Systematic investigation of material behavior and damage evolution across temperatures (650-850 °C) and speeds (10-29 mm/s).

Main Results:

• Higher workpiece temperatures reduce tool force but can cause surface damage at extreme levels.
• Lower forging speeds increase the risk of workpiece damage, while higher speeds prevent defects.
• Numerical simulations accurately predicted damage observed in experimental tests.

Conclusions:

• A balanced approach to forging temperature and speed is necessary for optimal CuZn40Pb2 processing.
• Integrated simulation and experimental methods effectively identify optimal forging parameters.
• Understanding parameter influence minimizes damage and enhances the hot forging of brass alloys.