This study investigates the closed-die hot forging process of a CuZn40Pb2 brass alloy water valve cover using a traditional single-stroke forging press. Key factors affecting defect formation in the material geometry include the cylindrical workpiece geometry and die temperature. The finite element model (FEM) developed to optimize temperature effects on material flow behavior was implemented using Deform® 3D software. The simulations considered geometry, filling order, and force as inputs. Experimental trials showed that the coefficient of friction, which decreases with lubricant use, significantly impacts material flow. This is because frictional forces during forging heat the dies, reducing the coefficient of friction and potentially increasing defect likelihood. Stress and strain analysis from the simulations indicated a complex interplay between temperature and friction coefficient, influencing defect formation. The experimental results aligned with the simulations, validating computational modeling as a tool for predicting and mitigating defects. This study offers valuable insights into the closed-die hot forging of CuZn40Pb2 brass alloy water valve covers, emphasizing the importance of temperature and friction control. These findings can improve forging process design and operation, leading to high-quality product production.
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