This study investigates the cold forging behavior of AISI 1045 steel through experimental tests and numerical simulation. Six cylindrical samples (25.4‐mm height, 25.4‐mm diameter) were compressed at reductions ranging from 10% to 50%. Barreling became evident at 30% deformation attributable to friction in the contact areas. Microhardness increased from approximately 280 ± 20 HV in the central zone to 300 ± 20 HV at the periphery, indicating strain hardening. In parallel, a numerical simulation was performed in ANSYS using static structural module, an axisymmetric model, mesh quality between 0.89 and 1. Additionally, a constant displacement and a friction coefficient of 0.05 between the die–part interfaces were considered as boundary conditions. A comparative analysis between experimental and simulated results showed barreling prediction accuracy within ±5%. These findings confirm the influence of friction and geometry on stress distribution and highlight the importance of controlling forging parameters to optimize mechanical properties.
Lorenzo-Galindo et al. (Thu,) studied this question.