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As a result of analyses on the ability of the free forging process to forge along the three geometric axes, we can conclude that the most favourable free forging operation is in the axial direction, which is a general conclusion for forging operations in the flat anvil case. However, the flat anvil rotation in forging operations with flat workpiece is the most favourable, because the absence of a clear geometric axis on which to apply the force is compensated by the use of rotation. Moreover, it is clear that the flat anvil perpendicular to the forging direction forms a potential geometric axis. Therefore, it is a think-positive decision to select the simplest geometric conformation in the component under consideration, in this case, the flat anvil with rotation.
Another significant advantage of the flat anvil rotation for the forging process is the possibility of the usage of the flat anvil to actively prepare the workpiece, i.e., by rotating the flat anvil, it is possible to increase the material density in the designated zone in the forging. From the figures, it can be noticed that there is a noticeable increase in material density in the area in between two anvil faces, even when the flat anvil is rotated. However, the use of rotation in the plan view of the anvil does not have an impact on the effective strain distribution over the forging volume. This anvil rotation is only an effective tool for increasing material density in the designated zone in the forging, but does not impact the effective stress and strain distribution over the forging volume.
Figures 18a-b show an example of metal distribution in the areas of the forging affected by anvil rotation. A closer look at Figure 18b reveals a 1 mmx1 mm area with a higher effective strain value, which is located in the section right in front of the anvils. This specific area of relatively high strain caused by the action of the flat anvil rotation can be regarded as a clear example of what we call forging quality; i.e., the metal flows freely in the part between the anvils, but prior to the action of the anvils, the metal flow was blocked. d2c66b5586