FEA modeling of effect of axial feeding velocity on strain field of rotary swaging process of pure magnesium

A coupled thermal-mechanical model of the rotary swaging of pure magnesium was developed using the general finite-element software program MSC/Marc to visualize the effect of axial feeding velocity on the rotary swaging process. The radial displacement occurring in one pulse impact increases in proportion to axial feeding velocity (νax). When the other processing parameters are fixed, the surface roughness of the swaged bar increases with νax and is in parabolic relation with νax. There exists a minimum velocity νax,min below which the decrease of νax will no longer improve the surface roughness. Under the technological conditions of this simulation, when the finial diameter d=6.6 mm, νax,min=1.82 m/min, and when d=7.0 mm, νax,min=1.83 m/min. If Ra=3.2 is required for the end product, then νax,max=6.02 m/min is gotten for d=6.6 mm and νax,max=7.05 m/min for d=7.0mm. The increase of νax has no notable influence on strain distribution along radial direction. The errors between the experimental and simulated height of the spiral spine-like ridges are below 8.0%.