Int J Mater Form (2008) Suppl 1:387 –390

DOI 10.1007/s12289-008-0076-2
# Springer/ESAFORM 2008

Recent development in orbital forging technology

J. Nowak1, L. Madej1, S. Ziolkiewicz2, A. Plewinski2, F. Grosman3, M. Pietrzyk1
1
Akademia Gromniczo-Hutnicza, al. Mickiewicza 30, 30-0159 Krakow, Poland.
URL: www.isim.agh.edu.pl e-mail: nowak, lmadej, [email protected];

2
Instytut Obrobki Plastycznej, ul. Jana Pawáa II 14, 61-139 Poznan, Poland.
URL: www.inop.poznan.pl
e-mail: ziolkiewicz, [email protected];
3
Politechnika Slaska, ul. Krasinskiego 8, 40-019 Katowice, Poland.
URL: /www.rm.polsl.pl/ e-mail: [email protected];

ABSTRACT: The main subject of the present work is investigation of possibility of extension of classical
orbital forging technology to obtain more cost effective forging process. Orbital forging is the process used
for forging of shaped parts by applying the incremental forging method. Results of simulation of orbital
forging are compared in the present work with the result obtained from a conventional forging process. 3D
finite element (FE) simulations are used in the present project to evaluate the capabilities of the orbital
forging process and proper die design, and to predict the forging loads the. Selected results of simulations are
presented in the paper. These results are the basis for the further comparison and discussion about possible
modifications of conventional orbital forging approach.

Key words: incremental forming, orbital forging, orbital press

1 INTRODUCTION

Advantages of incremental bulk forming are

well known in the literature [1-5]. This technology is
commonly applied in industrial conditions, to reduce
loads and to increase workability during forging in
comparison with the conventional monotonic
process. Another advantage is the possibility to
forge hardly formable materials and to obtain high
deformation degrees. On the other hand, many steps
are necessary in this process to obtain final shape of
the product, what extends the manufacturing time.
Typical examples of processes of incremental
forming are cross and profile rolling, open die
forging, rotary swaging or orbital forging (Figure 1)
[6]. Analysis of advantages and limitations of orbital
forging and investigation of possible improvement
in this technology are the subject of this work.
Orbital forging, presented in Figure 2, is used
for forging of shaped parts by applying the Figure 1. Examples of incremental forging processes.
incremental method. In this technology a sample is
placed between an orbiting upper die, that moves
towards the sample, and a non-rotating lower die. These two technologies have similar advantages
The lower die is properly shaped and is used to in comparison to conventional forging. The main
transfer the shape of the final part. The first advantage is load reduction and possibility to obtain
modification of this technology is to move the lower very large deformations without the danger of
die axially toward the upper die, that in this case is material failure.
fixed axially but still its axis makes orbital motions.
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region currently loaded by the rotating tool. Limited
region of deformation in the orbital press reflects
also in the distribution of the strain rates (Figure 5).
Presented above differences in metal flow during
deformation, may also be related to the differences
in temperature distribution (Figure 6). In the orbital
press high temperatures appear at the circumference.
Temperature distribution in the sample is more
uniform in the conventional process.

Table1. Process parameters

Parameter Value
Material steel 40H
Initial dimensions of the sample I30x30
Press velocity 2mm/s
Angular velocity of the die 400rpm
Figure 2. Schematic illustration of the orbital press. Main Initial temperature 650OC
dimensions used during numerical simulation are given in mm.

High smoothness of forging surface, material

economy, simple design and easily exchangeable
tools are also advantages of this technology. Forging
of wheel disks with hubs, gears, bearing rings, rings
of various contours, bearing-end covers etc., are
typical applications of the orbital process [2,7].
However, due to the nature of this process, some
surface deformation may occur in front of the
moving upper die. That in some cases leads to micro
crack initiation. Due to orbital movement, failure
can also initiate at the circumference of the sample.
A variety of orbital forging processes are
introduced in the industry in the word. The approach
proposed by Marciniak [8], where orbiting upper die
moves towards the sample, is considered below. Figure 3. Strain distribution in 3D obtained at the end of
Possibility of changing an inclination of the die is deformation in the orbital press.
the main feature of this process. The objective of the
work is to investigate potentials and limitations of
this technology and to recommend modifications.

2 SIMULATION OF THE ORBITAL FORGING

Main process parameters used in simulation of

deformation in the orbital press are gathered in
Table 1. Numerical simulations were performed with
the commercial Forge2005 software. Results
obtained for this process are compared with those
obtained for a conventional monotonic forging Figure 4. Strain distribution at the end of deformation in the
process. Strain distribution and final shape obtained conventional forging (a) and in the orbital press (b), scale as in
after the end of the orbital process are shown in Figure 3.
Figure 3. Comparison made at the cross section of
the strain values obtained using two forging Tendency to crack initiation in the two
approaches are presented in Figure 4. considered processes was investigated next.
It is seen in Figure 4b that due to orbital Calculated distributions of the Latham-Cockcroft
movement of the upper die strains in the upper part failure coefficient [9] are presented in Figure 7. The
of the sample are lower than in the conventional 3D distribution of the failure coefficient is presented
method. Similar values are observed only in the in Figure 8.