Analysis and study of geometric tool parameters with purpose increasing the quality of forgings during forging bodies of brass cranes

This paper presents an analysis of the plastic flow of the material, carried out on the basis of the QForm 3D software package in order to determine the optimal geometric parameters of the tool. The high demand for brass valves is increasing, which leads to the need to improve the quality and efficiency of production (in particular, reducing the metal consumption of semi-finished products). This article discusses the schemes of hot forging of brass bodies of ball valves for fastening the body of the electric drive. In the process of pilot development, a clamp (contact of the workpiece planes) was revealed at the end of the forging, which opened after machining. This defect is the final marriage, which led to the need for simulation in the QForm 3D software package to determine the causes of its occurrence and adjust the technology. According to the simulation results, the formation of a clamp occurs when the belt of material moving towards the upper punch is thinned, which leads to its cooling and an increase in the tensile strength. Further deformation is accompanied by the penetration of a cooled and more durable brass band into the body of the workpiece. Simulation data made it possible to correct the geometry of the tool (increase the diameter of the punch), which made it possible to provide a wide belt between the internal cavity of the die and the outer diameter of the punch during the formation of the forging, which made it possible to maintain the temperature of the workpiece. Uniform temperature distribution allows maintaining the isotropy of mechanical properties over the workpiece body and ensuring stable plastic deformation without the appearance of a clamp. The goals and objectives of further research of the process are determined, related to the determination of the ratios of the geometric parameters of the tool for making recommendations for the design of the tooling. It is planned to conduct a physical experiment and a comparative analysis with the results of modeling in finite element packages, which will make it possible to establish a correspondence between the physical and mathematical models.