New insight into the radial forging process by an asymptotic-based axisymmetric analysis.

• An asymptotic analysis is performed for modeling radial forging process. • It can predict the material flow inhomogeneity and deviation of neutral points profile. • A process feasibility criterion is developed in terms of the die angle, friction and back-push stress for the 1st time. • A breakthrough method is proposed that can effectively find the location of the neutral plane far easier and faster. In this paper, an analytical approach based on the asymptotic analysis is proposed to develop an axisymmetric model for the radial forging process of rods. This model is able to predict the deformation inhomogeneity in the radial direction and approves that the profile of the neutral plane is not a planar cross section of the workpiece. For the first time, a relationship has been developed between the die angle, friction coefficient and back-push stress that can be used as a criterion for examining the feasibility of the radial forging process. A breakthrough method has also been proposed that can effectively find the location of the neutral plane far easier and faster than the traditional approach. Finite element simulation of the process has been performed to validate the deformation pattern obtained by the asymptotic model. Models are also verified against available experimental data. The findings of this study are especially useful for online design, analysis and control of the radial forging process. [ABSTRACT FROM AUTHOR]