Optimization of Hot Forging Process Parameters of Alloy CuZn40Pb2 Using an Experimental and Numerical Approach

The optimization of hot forging process parameters plays a critical role in enhancing the mechanical properties and overall performance of the alloy CuZn40Pb2. This study presents an innovative integrated approach that combines experimental investigations with numerical simulations to optimize the forging parameters of the brass alloy CuZn40Pb2. The methodology aims to prevent damage during the forging process by identifying optimal deformation temperatures and forging speeds. The influence of these parameters on material behavior and damage evolution was systematically investigated through both numerical simulations and experimental tests, within a deformation temperature range of 650 to 850 °C and forging speeds from 10 to 29 mm/s. For the experimental approach, forging tests were conducted by using a mechanical press. Forging process simulations were conducted using the FORGE FE software, which uses the Hensel–Spittel constitutive model to characterize material behavior. A comparison was made between numerical simulations and experimental tests to enhance the forging process for optimal results and minimize the risk of damage to the forged product. The analysis results indicate that an increase in the workpiece temperature is correlated with a reduction in the tool force. Nevertheless, at exceptionally high temperatures, the surfaces of the pieces undergo damage. Similarly, regarding the speed parameter, lower values may result in workpiece damage due to the lateness of the process. This damage corresponds to that identified during the numerical simulations. However, at higher values, the workpiece does not contain defects. Hence, a judicious compromise in the parameter settings during the forging process is deemed necessary to optimize the forging process of CuZn40Pb2.