Obiko, JaphethShongwe, BrendonMalatji, NicholasBodunrin, MichaelKlenam, Desmond2025-03-242025-03-242024-05-272468-2276 (E)https://doi.org/10.1016/j.sciaf.2024.e02265https://hdl.handle.net/20.500.14519/1535This paper presents results on the effect of aspect ratio on the flow stress of 42CrMo4 steel using Deform™ 3D Version 11 simulation software. The FEM simulation process conditions were upsetting temperature of 1000 ◦C and 10 s⁻1 strain rate. The sample aspect ratios (height/diameter) varied within commonly used ranges during conventional Gleeble experimentations. The aspect ratio did not affect the flow stress behaviour during forming. Generally, the forming conditions influence the flow stress-strain field and distribution behaviour, causing inhomogeneous deformation. A negligible effect of aspect ratio on typical industrial forging process is only attainable between 1.0 and 2.0. The implications of the results for industrial forging are elucidated.1-7 PagesenAttribution-NonCommercial-ShareAlike 4.0 Internationalhttp://creativecommons.org/licenses/by-nc-sa/4.0/Forging simulationEffective stressMetal flowDeform™ 3DEffective strainArticle