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The Prediction of Microstructures during Forging Operations

Researcher: Gavin Yearwood

Collaborator(s): Dr. Mark Ward & Dr. Hector Basoalto

Microstructural properties formed during a Forging operation can have significant impact upon the properties of the component after Forging. This project aims to use the finite element software Forge by Transvalor to predict the microstructural properties in forged components.

Experimental procedures will validate the boundary conditions considered in the FE model, as well as validate the modelled predictions for grain size measurements.  For each forged component examined, an accurate FE model is built to best replicate the actual processing conditions. The FE model produces results which can be analysed and compared with the actual forgings. The modelled results give a guide to how the grain-size calculation works within Forge, and how sensitive the modelled predictions are to strain, strain rate, initial grain size and temperature.

The forging process parameters implemented in the FE software are varied, to match those found in literature; to see the effect on the model and the predicted microstructure. To gain further understanding in to how the Forge software calculates grain size, tracking points are attached to the simulated billet, to record information at those specific nodes. This data is then utilised in a MatLab code to determine whether the Forge predictions for recrystallisation could be replicated. This offers a greater understanding of the FE software code.

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