Improvement of upsetting process of four-beam workpieces based on computerized and physical modeling

The method of upsetting of large ingots has been investigated in this work. The proposed method consists in upsetting of profiled workpieces with concave faces. An angle of the concave faces was 150°. A relative depth of the concave faces has been varied in range 15%…25% from workpiece's diameter. Strains effective and mean stresses in the longitudinal cross-section of the workpiece with concave faces after upsetting have been determined by FEM. A value of compressive stresses has been determined based on a parameter of the stress state. FEM allowed to find what a rational depth of the concave faces should be, which has to be 15 % from workpiece's diameter. Maximum closing of the internal defect take place for this depth of the concave faces. Results of the FEM have been tested by experimental investigations. It has been established that upsetting of the four-beam workpieces improved a quality of the massive parts.