Visualization of Metal Flow in Forming Processes and Forging Process Design

Metal flow representing continuous plastic deformation in a metal forming process is visualized by mathematical tequnique such as FEM analysis or by experimental tequnique such as Visioplasticity method. The authors developed the physical simulation system by which a metal flow characteristics and strain conditions in the workpiece can be visualized quantitatively in the realistic deformation conditions. The flow field can be observed from the distortion of grid pattern which has been placed by print or by machining on the observation plane in the physical simulation.Model material, Plasticine in the present workpiece, or actual material, was deformed by in-cremental steps, and the metal flow and strain condition in a workpiece in non-steady state deformation condition could be observed and determined by numerical analyses. The above procedure was applied to optimal process design of bolt head forging process, heading.