Finite element calculation of thermal coupling between workpiece and tools in forging

A finite‐element model for calculating the die temperature profile for a hot‐forging operation is presented. The workpiece is modelled as a thermo‐viscoplastic material, while the dies are considered undeformable. Heat transfer between the dies and the workpiece is modelled using an iteratively coupled,fixed‐point calculation of the temperature in each domain. Transfer of temperature boundary conditions across contact interfaces is performed for non‐coincident meshes, using a boundary integration point contact analysis. Two industrial‐type examples are presented. In the first example,the effectiveness of the transfer of the temperature boundary conditions for a non steady‐state forging process is evaluated and determined to be satisfactory. Then weakly‐ and strongly‐coupled temperature resolutions are compared. It was found that the strongly‐coupled resolution may be necessary in order to obtain reasonably accurate results. In the second example, the weakly‐coupled resolution is compared to a constant‐temperature die approach for a relatively slow forging process, which shows the influence of the die temperature on the flow of the material.