Simulation of the Heading Process

Abstract

Plasticine, Commercially Pure Lead and 6061T6 Aluminum have been used as model materials to simulate some of the forming processes that can arise during a first blow axisymmetric heading operation namely; upsetting, forming into a die cavity and the free flow operation. The deformation characteristics have been studied in each of these operations and some gross internal flow patterns have been determined using multilayer plasticine workpieces. The influence of both the operation and the workpiece geometry on the heading forces was also investigated. Some simple analytical models based mainly on the Load Bounding Techniques have been employed to predict the heading forces. Reasonable agreement was observed between the theoretical and experimental results.