Numerical Simulation of Upsetting and Stretching Process for Heavy Forgings with 1750 mm Diameter

The heavy forging used as squeeze roller is a key component of grinding machine for cement production with the largest diameter 1750 mm larger than its length 1260 mm. If the heavy forgings are forged with the traditional process of one time upsetting and stretching, a heavy ingot 125t upsetted to more than 3000 mm diameter is needed, which goes beyond the forging capacity of current 8400t hydraulic press machine. So forging process of two times upsetting and stretching process is proposd. Based on three-dimension software, the first process of the two times upsetting and stretching is simulated theoretically for the heavy forgings. Simulation results of WHF-stretching and FM-stretching after first upsetting shows that by upsetting and WHF-stretching compressive stress not only eliminates voids at re-crystallization temperature, also obtains better forging penetration ability. The eight manufactured forgings all up to supersonic standard prove the feasibility of the techniques.