Prediction of contact pressure, slip distance and wear in cold rotary forging using finite element methods

This paper aims to utilize finite element (FE) methods to predict the wear of dies and workpiece in cold rotary forging through systematically investigating the contact pressure and the contact slip distance. For this purpose, a 3D elastic-plastic FE model of cold rotary forging is developed using the FE code ABAQUS. Using this reliable 3D FE model, the evolution and the distribution of contact pressure and contact slip distance are investigated in detail. Consequently, a new insight into the wear that occurs at the surfaces of the dies and the workpiece is gained based on Archard's wear law.

► The calculations of contact pressure and slip distance are resolved reasonably. ► This study predicts the wear in a complex continuous local forming process of cold rotary forging. ► This study numerically reveals wear responses by analyzing contact pressure and slip distance.