Comparison of physical and virtual simulation of multi-axial forging processes on EN-AW 6082 aluminium alloy

Abstract The multiaxial deformation of EN-AW 6082 Aluminium alloy samples was performed by a Gleeble 3800 thermo-physical simulator equipped with MaxStrain system. The samples were cyclic forged so, that the accumulated equivalent plastic strain increased by the nearly same at every step. The increment of plastic strain was about 0.4, while the maximal equivalent strain was around 4. Between forging steps, pictures were made about the deformation zone of the samples to track the geometric deformation. The simulator was programmed to implement different strain rates at ambient temperature. The tested strain rate was 0.1 1/s. The unforeseeable temperature increase due to the plastic deformation was measured by thermoelements connected next to the deformation zone. The finite element model of the physical simulations was created in QForm3D 9.0.9. software. During the physical simulation, tool movements and temperature were recorded. These movements were used in the virtual simulation to control the process. The Temperature-Time and Force-Displacement curves of the simulations were compared to evaluate the finite element model.