Billet Size Optimization for Hot Forging of AISI 1045 Medium Carbon Steel Using Zener-Hollomon and Cingara-McQueen Models

This study investigates the effects of initial billet size variations on material flow behavior in hot forging processes, aiming to optimize the forging process using validated predictive models. Material and high-temperature compressive tests inform mathematical models, while simulations are conducted via the finite element method (FEM). Results align with the Zener-Hollomon and Cingara-McQueen approaches. The Arrhenius model predicts AISI 1045 steel flow stress with an R² of 0.968 and an average absolute relative error (AARE) of 7.079%. The Cingara-McQueen equation achieves an R² of 0.997 and an AARE of 2.960%. Reducing billets size from 260 mm to 230 mm decreases the material usage by up to 11.5%, while maintaining workpiece integrity. Experimental and simulated loads exhibit an AARE of about 2.69%, thereby indicating potential cost and efficiency improvements in hot forging processes.