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Orbital forging is a relatively new process for the plastic forming of metal. It has many advantages over the conventional forging processes, especially the lower forming load. However different process parameters must be considered in orbital forging due to the special die kinematics. the prupoe of this study is to investigate the influence of these process parameters by using the finite element code DEFORM-3D to simulate the orbital upsetting process.
Through the systematic simulation studies, the critical process parameters such as the feeding rate of the die, the rocking angle and rotation frequency of the upper die and the billet geometry were identified. The effects of these process parameters on the foreing load, the geometry defects and profile of forged billet and also the stress of die were studied in this thesis.
Finally, some useful guidelines for selecting the process parameters of orbital forging based on the analysis results of process parameters were obtained.
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