A Study Utilizing Numerical Simulation and Experimental Analysis to Predict and Optimize Flange-Forming Force in Open-Die Forging of C45 Billet Tubes

Open-die forging holds a pivotal role in shaping machine parts within industrial applications. This study focuses on the assessment of stress–strain curves for C45 material at different elevated temperatures and strain rates through numerical simulations employing finite element method (FEM). Specifically, research investigates how flow curve materials individual impacts forming force during flange billet tubes. By comparing simulation results with experimental data flange-forming force, this observes that optimal outcomes arise when considering both temperature materials. The then conducts tubes varying upsetting ratios (H0/D0), (S0/D0), punch’s pitch angle (α), aiming to address optimization challenges related force. Consequently, mathematical model is developed represent relationship between geometric parameters (H0/D0, S0/D0, α). accurately predicts under various conditions, demonstrating high precision maximum error 4.26% compared results. significantly contributes advancement technology open-die simulation, enabling selection appropriate equipment. These findings pave way more effective efficient processes, fostering innovation progress field.