Behzad Pasoodeh - PhD Student, Faculty of Mechanical Engineering, Department of Engineering, Urmia University, Urmia, Iran
Vali Alimirzaloo - Assistant Prof, Faculty of Mechanical Engineering, Department of Engineering, Urmia University, Urmia, Iran
Hadi Tagimalek - PhD Student, Faculty of Mechanical Engineering, Semnan University, Semnan, Iran

Regarding comprehensively the evaluation of the plastic deformation, damage condition and strain distribution of the AISI-۱۰۴۵ steel, the numerical and experimental investigations of the upsetting process of the hexagonal cylinder has been carried out. Investigating of the former papers revealed the lack of the study of the hexagonal billet. Therefore, it was decided to fill this gap in this paper. To implement upsetting testes, the finite element code of DEFORM-۳D software was applied, and the effective stress, effective strain distribution, damage and strain non-- uniformity were achieved. Based on the above-mentioned parameters and the finite element method results, the deformation crack defect evaluation was developed and it was found out that the cracks will mostly be appeared on the top of the side edges meaning that part of the forged cylindrical billet enjoys the most critical plastic strain and are about to fail before other regions. Ultimately, further findings revealed that under the tri-lateral compression of hexagon cylinder, the uncoordinated deformation mechanism is probably the main source directing to crack defect. Furthermore, in order to validate the results of the numerical results, the experimental studies were also taken by test machine SANTAM-۱۰۰ placed in laboratory and its results showed a suitable agreement with simulation findings.

Crack analysis Hexagonal billet Strain non-uniformity Strain distribution Simulation