Evaluation of Hot Forging Billet Size through Compressive Testing Using Zener-Hollomon and Cingara Variables

This study investigates the widespread utilization of AISI 1045 carbon steel in the automotive hot metal forming industry. The primary objective is to research material data to enhance cost-efficiency and industrial competitiveness. High-temperature compressive tests are conducted at temperatures ranging from 900 to 1200 °C and strain rates from 0.1 to 10 s^-1. The Zener-Hollomon equation identifies key variables for assessing high-temperature flow behavior, and the Cingara equation explores maximum flow stress. The data collected is then used in finite element analysis to compare with actual test results, offering insights into optimizing manufacturing processes and competitiveness. The experimental findings demonstrate a close and accurate correlation between the material data and the generated simulation model, yielding reliable approximations of the actual test results. Furthermore, a reduction in material usage of up to 11.5 % can be achieved, decreasing it from 260 mm to 230 mm without compromising the integrity of the workpiece.