Corner filling characteristics in precision forging

Abstract The filling of corners in flashless forging of cylindrical shapes is considered. Experiments with commercially pure aluminium were carried out at room temperature and the effects of different workpiece geometries and lubrication on corner filling were observed. Three different upper bound solutions are applied to predict tool loads and metal flow. The extent of agreement between each of these and experimental results depends on billet geometry and boundary conditions. It is demonstrated that the velocity field which leads to the best load prediction is not that which most closely describes changes of geometry in a billet.