The Modelling of the Mechanics of Deformation in Plane Strain Upsetting of Round Cross-Section Billets Between the Flat and V-Shaped Dies

Plane strain upsetting of round cross-section billets between the flat and V-shaped dies has been studied in this paper. A deformation model has been proposed and the geometry of the deformed billet cross-section is determined for a given displacement of the top flat die. To analyze the process, the slab method of analysis has been applied and for a given process conditions, the required forming load has been estimated. The process under consideration has been performed also with the finite-element method to predict the forming load and the material flow. The calculated forming load and the deformed billet cross-section geometry compare well with the FE simulations data. The effects of friction factor and the angle of the V-shaped bottom die on the forming load have been investigated. The theoretical results have been indicated that as the bottom die angle decreases the forming load decreases and the forming load is not influenced by friction in case of small bottom die angles.