Computer modelling of valve lever forging with various preforms

Application of CAE has become a common way to decrease a time for process planning and tool design in metal forming. Continuous development of numerical methods and software has provided advanced possibilities to solve various problems. In this paper a thermo-mechanical analysis of valve lever forging by means of SuperForge software was presented. There were taken into account various geometries of preforms, changes in temperature and internal stress distributions during subsequent forging stages in order to optimize metal flow. As the result, complete filling of die cavity without overlaps as well as reduction of flash volume has been obtained. Additionally, values of deformation force components (including side forces) were calculated what was helpful in a proper die design with counterlocks.