Sensitivity Analysis of the Barreling Behavior of an Axisymmetric Bimetallic Cylinder in Open-Die Forging

Nowadays, bimetallic components play a significant role in weight reduction and manufacturing cost savings. Open-die forging is one of the key bulk forming processes applicable to such components. However, one of the common defects in this process is barreling, which can increase production time and costs. This study investigates the sensitivity of the barreling behavior of an aluminum–steel bimetallic cylindrical component during open-die forging. Owing to the bimetallic structure, the barreling behavior of both core and shell was independently analyzed with respect to process parameters, including the shell diameter, the friction coefficient between the core and shell, and the friction coefficient between the workpiece and die using FEM simulation and full factorial design of experiment. The optimization process was carried out using ModeFrontier, and the results were evaluated through ANOVA sensitivity analysis. The results indicate that the initial outer radius of the shell has the greatest influence on the barreling of the shell and core barreling. Conversely, the core–die friction coefficient has a significant effect on the barreling of the core after deformation.

کلیدواژه ها:

Bimetallic component ، Open-die forging ، Barreling ، ModeFrontier