FEM Analysis of Void Closure Behaviour during Open Die Forging of Rectangular Billets

Finite element analysis of open die forging to make rectangular billets has been performed in this study. Three‐dimensional rigid‐plastic finite element method (FEM) was used to analyse the effects of process variables, forging pass design and die configurations on the void closure phenomena. The major objective was to control the internal deformation for better structural homogeneity and centreline consolidation of the rectangular billet. The effect of die width ratio, die feed rate, die shape, and number of passes on the void closure ratio has been examined. Although it is difficult to optimize process parameters in industrial environments, favourable process conditions are recommended to achieve better product quality.