Optimizing the hot-forging process parameters for connecting rods made of PM titanium alloy

One of the major concerns for industries in the modern world is to focus efforts on producing high quality products with minimal costs. Various quality improvement philosophies have emerged in recent times, Six Sigma being one of the most practical and efficient techniques for quality improvement of processes. In this work, Six Sigma based DMAIC (Define, Measure, Analyze, Improve, Control) approach is used to enhance productivity and quality performance, and to make the hot forging process robust to quality variations. Finite element method has been employed for the simulation of hot forging of the connecting rod. The influence of design and process parameters is investigated for the response ‘forging die load’. Analysis of various critical parameters and the interaction among them has been carried out with the help of Taguchi’s method of experimental design. To further optimize the response and make the analysis more precise and robust, response surface methodology has been incorporated. Parameters have been optimized, leading to the accomplishment of a minimized forging die load which is verified using a confirmation experiment. Confirmatory results reveal the potential of the DMAIC approach of Six Sigma in optimizing the process parameters successfully and thereby present significant applicability in the industry.

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Study on the Formability of Magnesium Alloy Parts Under Hot Forging Process

Volume 4: Advanced Manufacturing Processes; Biomedical Engineering; Multiscale Mechanics of Biological Tissues; Sciences, Engineering and Education; Multiphysics; Emerging Technologies for Inspection ◽

10.1115/esda2012-82021 ◽

2012 ◽

Author(s):

Su-Hai Hsiang ◽

Yi-Cheng Hong ◽

Huey-Lin Ho ◽

Shiuh-Kuang Yang

Keyword(s):

Magnesium Alloy ◽

Process Parameters ◽

Hot Forging ◽

Experimental Conditions ◽

Forging Process ◽

Finite Element Software ◽

Metallographic Observation ◽

Deformation Behaviors ◽

Simulation Results ◽

Hot Forging Process

This study investigates the formability of AZ31 and AZ61 magnesium alloy for bicycle parts under hot forging process. Firstly, finite element software DEFORM is applied to simulate the deformation behaviors of magnesium alloys bicycle parts under different process parameters. The process parameters considered in the simulation are materials heating temperatures, lubricants and punch speeds. Changes in process parameters, the forging loads and the completeness of filling of material in die cavity are discussed. The optimal forging condition can be obtained from evaluation of the completeness of filling of material in die cavity, forging load and distribution of stress and strain. The experimental conditions are set according to the optimal simulation results. Hot forging experiments are carried out under the condition of heating range from 240°C to 350°C, different kind of lubricants, constant punch speeds 0.9mm/s to study the formability of magnesium alloy for bicycle parts. The experimental results are compare with the DEFORM simulation results. The obtained forging loads and completeness of filling are in good agreement with the simulation results. The validity of the simulation model established in this study can be confirmed. Finally, from the measured result of hardness and metallographic observation of forged part, the influence of forging temperatures on the strength and microstructures of magnesium alloy for bicycle parts under forging process can be evaluated.

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Coupled Thermo-Mechanical-Metallurgical Analysis of an Hot Forging Process of Titanium Alloy

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.554-557.638 ◽

2013 ◽

Vol 554-557 ◽

pp. 638-646 ◽

Cited By ~ 2

Author(s):

Antonino Ducato ◽

Livan Fratini ◽

Fabrizio Micari

Keyword(s):

Titanium Alloy ◽

Phase Distribution ◽

Hot Forging ◽

Point Of View ◽

Forming Process ◽

Forging Process ◽

Mechanical Evolution ◽

History Of ◽

Implicit Code ◽

Hot Forging Process

In the present paper a numerical FEM model for the analysis of a forming process of a complex shape component is presented. The model, developed using the commercial implicit code DEFORM™, can take into account both the thermo-mechanical evolution and the microstructural evolution of the considered material. In this case the Ti-6Al-4V titanium alloy was because it was possible to carry out a very good characterization into a FEM ambient. In particular the code can calculate the phase distribution of the main phases of the alloy as consequence of the thermo-mechanical history of the material during a hot forging process. At the end of the simulation the output data was showing to analyze the validity and the quality of the model by a numerical point of view.

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