The evolution of the compaction process and the deformed state of porous blanks during their hot forging in the open die

The article presents the results of the study of the evolution of the deformed state of the workpieces, the energetic parameters of the process and the distribution of porosity over the volume of the forging at all stages of hot forging of porous powder forgings in an open die. Modeling of the process was carried out using the finite element method using the DEFORM 2D/3D software complex. As a result of the simulation, it was found that at the initial stage of the process, the blank is mainly compacted with minimal radial flow of the material. Noticeable flow of metal into the groove groove area begins only when the forging material reaches an average relative density exceeding 90%. A significantly different nature of the distribution of axial er and radial ez deformations over the volume of the forging was noted. A zone with increased levels of values of axial deformations is formed in the central layer of the forging, equidistant from the upper and lower surfaces of the die cavity, and the values of radial deformations decrease with distance from the zone bordering the free side surface of the workpiece in the radial (to-center) direction. The minimum values of ez and er appear in the upper and lower angular stagnant zones of the forging. It is shown that the graph of the dependence of the deformation force on the displacement of the punch is marked by the presence of at least three characteristic sections due to the relationship between the processes of compaction and forging shape change at each stage of the process.