Development of Software for Billet Barreling Predicting at the Desing of Metalforming Processes Based on Pre-Upsetting

The development and automation of a methodology for determining the deformation unevenness in the form of barreling during the pre-upsetting of billets with flat dies are carried out. The urgency of the problem is to establish the feasibility of two directions: (a) the need to predict the value of barreling to achieve a complex energy-saving effect in metal forming technologies, (b) the development of separate software for processing experimental data to eliminate the use of expensive CAE-systems for simulation. The calculation method is based on the barreling coefficient’s exponential mathematical dependence on the cylindrical billet’s initial geometric dimensions, the degree of upsetting strain, and the required coefficients characterizing the properties of the billet material and the thermomechanical conditions of deformation. Software testing has shown that the average error between the results of the barrel coefficient calculations according to the developed model and the experimental data is 8.1%.