Citation :

Sayali Kulkarni, D.N. Raut, Rahul Warghane, Atul Jade, "Investigation of Deformation Characteristics in Forging through Mathematical Modelling and Microstructure Evolution Analysis," International Journal of Mechanical Engineering, vol. 13, no. 7, pp. 132-144, 2026. Crossref, https://doi.org/10.14445/23488360/IJME-V13I7P111

Abstract

Forging is a complex manufacturing process in which materials undergo continuous and non-uniform deformation. The deformation pattern varies across different sections of a forged component. This variation occurs due to geometry-dependent material flow. As a result, it becomes difficult to define a single deformation pattern or failure mode for complex forgings. These limitations have constrained advancements, leading forging process design to remain primarily dependent on experimental trial-and-error approaches. Existing experimental design approaches face challenges, including arbitrary outcomes, elevated costs, artificial conditions, and the lack of standardized design parameters, necessitating further development. To address the limitations of this methodology, a material failure mode–based design formulation has been developed. Critical performance parameters in the forging process are identified through operational studies and micromechanical analysis of material flow. Individual mathematical models are formulated for each performance parameter, and their functional relationships are established using statistical computing techniques. The statistical analysis includes the evaluation of process parameters, stress distribution, and material failure behaviour. The hidden hierarchical relationships within experimental data are identified using an advanced soft computing tool (cftool). Since forging is a sequential process, parameter selection is carried out with the primary objective of minimizing forging force. Mathematical modelling based on material failure theories and MATLAB curve-fitting results is employed to derive functional relationships among dependent parameters. A standardized design template is developed in MATLAB to determine optimal process parameters. The parameters obtained from the design calculator are validated by comparison with experimental data reported in the literature. A correlation-based evaluation approach is adopted to assess the effectiveness of the proposed methodology, achieving a 93% correlation between experimental results and model predictions. The validated design methodology is further evaluated through experimental trials on a developed forged component. Microstructural analysis of the forged component is conducted and compared with the base material to examine grain evolution during forging. The microstructural, morphological, and metallographic analyses confirm that the material behaviour and property development closely align with the predictions made during the design formulation stage.

Keywords

Cup-shaped forging, Design Experimentation, MATLAB Calculator, Forging design simulation, Micro-structure study.

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