Numerical determination of blank shapes for warm forming of non-axisymmetric components

This paper presents a numerical approach to accurately determine blank shapes for warm forming non-axisymmetric components with the aid of computer simulations. An intricate watch-case-like component made of stainless steel AISI 316L was used as an example to demonstrate this approach. The metal thickness t and the diameter of the center-hole d are crucial geometric variables of blank shape. Four different blank shapes with varying t and d were numerically predicted for performing the warm forming simulations. The results of the simulations showed that the flash at parting lines on both the inner and outer profiles of the formed components showed noticeable volumetric changes with different designs of blank shapes. Specimens were made according to the optimal design and the experiments were then carried out to verify the simulations. The overall appearance and dimensions of the warm-formed component was very close to those found in the simulation. This approach on this case was, therefore, demonstrated to be successful and could benefit the metal forming industry enormously.