In upsetting process, an initial block of metal (billet) is compressed between two or more dies to produce a complex part. Geometry of the final product is strongly dependent on the shape of initial work piece as well as on the perform shapes at each of the subsequent forming stages. Design of the optimum preform for near net shape manufacturing is a crucial step in the designing of many upsetted products of mild steel. In this study, the same is realized by using profile map, which is generated using the results of FE simulations of varying geometrical and processing parameters. The map is further verified experimentally using a mild steel specimen. It is shown that preform designed on the basis of profile map results in near net shape manufacturing. Such map offers a powerful tool for near net shape upsetting.
perform; finite element; upsetting; profile map; near net shape
