Simulation of 42CrMo steel billet upsetting and its defects analyses during forming process based on the software DEFORM-3D

In order to study the plastic deformation characteristics of 42CrMo steel in upsetting process and find out the feasibility of using computer simulation to analyze and research the upsetting process of the 42CrMo billet, by means of commercial and professional plastic forming software DEFORM-3D, the forging process of 42CrMo billet was simulated. It is concluded that (1) the changes of the temperatures, stresses and strains at the different regions of the billet were simulated during the entire forging process, (2) based on the stress and strain distributions of the forged billet, the forming defects analyze was proceeded and it is concluded that some forging defects or flaw may occur near the head surface or around the side edge during the plastic deformation process.