A finite element modeling method for predicting the cold radial forging quality of 20CrMnTiH hollow shaft: study of material composition and heat treatment parameters

• Published in: International journal of advanced manufacturing technology Vol. 139; no. 1; pp. 355 - 377
• Main Authors: Xu, Wenxia, Wang, Zhaohui, Zhu, Xuwen, Zhang, Bowen, Zheng, Zecheng, Lv, Mi, Wang, Hongxia
• Format: Journal Article
• Language: English
• Published: London Springer London 01.07.2025; Springer Nature B.V
• Subjects: Alloying effects; Alloying elements; Alloys; Annealing; CAE) and Design; Carbon; Cold; Cold forging; Composition; Computer simulation; Computer-Aided Engineering (CAD; Cooling; Damage; Deformation; Efficiency; Engineering; Experiments; Finite element method; Heat treatment; Industrial and Production Engineering; Mathematical analysis; Mathematical models; Mechanical Engineering; Mechanical properties; Media Management; Metal fatigue; Optimization; Original Article; Phase diagrams; Process parameters; Quality control; Radial forging; Residual stress; Simulation; Simulation models; Software; Spheroidizing; Strain; Temperature; Variables; Variance analysis; Spheroidizing annealing; Tukey’s post hoc test; Cold radial forging; Alloy composition; Variance analysis
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-025-15880-6

To fulfill the high efficiency and high precision requirements of the cold radial forging (CRF) process in the production of rotating parts, this research innovatively combines the optimization of alloy composition and the adjustment of heat treatment process parameters. The research focuses on the 20CrMnTiH hollow shaft as the subject of investigation, and the quality of machined parts was evaluated comprehensively by constructing an evaluation system based on residual stress, effective strain, and damage. The numerical simulation of spheroidizing annealing (SA) and the CRF process was realized by the phase diagram calculation method (CALPHAD) and finite element simulation model, and the feasibility of the simulation was verified by experiments. The comprehensive effects of alloying elements and heat treatment parameters on forming quality were deeply analyzed by variance analysis and Tukey’s post hoc test, and the significance sequence of each factor on hardness, residual stress, effective strain, and damage was revealed. Finally, the optimum combination of alloy composition and heat treatment parameters was determined, which significantly improved the properties and molding quality of the material. This study not only breaks through the limitations of traditional trial and error experiments, but also provides an efficient pre-screening method for material design and heat treatment process optimization in engineering applications, demonstrating the great potential of numerical simulation technology in process optimization and quality control.