Simulation of large forging flat-anvil stretching process and its optimization

In this paper, a kind of mathematic method for optimizing stretching process of large forgings is proposed. Distributions of effective strain within forged ingots is described by a Gauss function, which is obtained from the simulation of flat-anvil stretching process. Successive stretching is expressed by the superimposing Gauss functions. Optimized stretching process, with both homogeneous and certain strain in the center of forgings, is presented by derivation of this function. The relationship between effective strain and the values of feed is obtained during the successive stretching with a rotation angle of 90° and a feed displacement of 1/2 anvil width. The optimization result is verified by finite element simulation. Optimized value of feed obtained using this method can ensure both uniformity and forging penetration. It provides mathematic model and theoretic basis of optimizing large forging stretching process.     

Establishment of particular methods in casting simulation

Casting simulation tool ADSTEFAN is useful to design casting technology of complicated iron castings. Based on the function of solidification analysis, special methods were taken to carry out the prediction and optimization of shake-out timing for large sized iron castings. It has been proved that these analyses are effective to iron casting production. During the research of cast iron semi-solid process, to predict and control the influence of inclined cooling plate on flow and heat transmission of molten iron, the basis of analysis model has been built in this study. Flow field simulation considering temperature field was carried out for further research and satisfied with the practical production.