Study on investigation of hot forging die wear analysis – An industrial case study

Taking the forging die of an automobile differential shell as example, the influence of some die forging process parameters and die structure parameters on the die wear was investigated. Based on a modified Archard wear model and the application of finite element method simulation, the die wear depth was calculated under a steady state temperature field. Within the scope of the experimental data, the research shows that: with the increase of billet preheating temperature, the wear is reduced gradually. Improving die preheating temperature, the wear increases gradually. When the forming speed is 300mm/s~400mm/s, the wear value decreases first and then increases.When the forming speed is over than 400mm/s, the change of wear value is not obvious. Increasing flash thickness and round radius, the wear value reduces gradually.

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Filling Path Planning and Polygon Operations for Wire Arc Additive Manufacturing Process

Mathematical Problems in Engineering ◽

10.1155/2021/6683319 ◽

2021 ◽

Vol 2021 ◽

pp. 1-12

Author(s):

Jiansheng Zhang ◽

Qiuyun Wang ◽

Guiqian Xiao ◽

Jie Zhou

Keyword(s):

High Temperature ◽

Additive Manufacturing ◽

Path Planning ◽

Attitude Control ◽

Hot Forging ◽

Outer Contour ◽

Hot Forging Die ◽

Forging Die ◽

Wire Arc Additive Manufacturing ◽

Filling Path

To improve the service life of hot forging die, the additive manufacturing algorithm and additive manufacturing device for die remanufacturing are developed. Firstly, a compound filling algorithm in which the inner zone is filled by linear scanning and the outer contour is filled by offsetting is developed in order to solve the problems encountered in filling path planning for wire arc additive manufacturing (WAAM) like staircase effect at marginal division, degenerated edge at outer contour, programming difficulty, and so forth. Meanwhile, the attitude control algorithm of welding gun is proposed to control the angle between welding gun and welding path so as to improve the welding forming quality. Secondly, the high-temperature and low-temperature wear resistances of Fe-based and Ni-based alloy are tested. The results show that Ni-based alloy has higher high-temperature wear resistance. Finally, a disabled crankshaft hot forging die is selected for application test and the results show that, using the techniques discussed in this paper, welding materials can be saved by more than 50% and machining cost can be saved by more than 60%. In addition, the surface of automatic-repaired die is smooth without oxidation, collapse, and other defects after forging 3000 times, which is much better than that of manual-repaired die.

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Simulation of Deformation Behavior and Microstructure Evolution during Hot Forging of TC11 Titanium Alloy

Defect and Diffusion Forum ◽

10.4028/www.scientific.net/ddf.385.449 ◽

2018 ◽

Vol 385 ◽

pp. 449-454 ◽

Cited By ~ 3

Author(s):

Artem Alimov ◽

Dmitry Zabelyan ◽

Igor Burlakov ◽

Igor Korotkov ◽

Yuri Gladkov

Keyword(s):

Titanium Alloy ◽

Microstructure Evolution ◽

Technology Development ◽

Hot Forging ◽

Industrial Case Study ◽

Aerospace Applications ◽

Heating And Cooling ◽

Tc11 Titanium Alloy ◽

Kinetics Of

Finite element method is the most powerful tool for development and optimization of the metal forming processes. Analysis of titanium alloy critical parts should include the prediction of microstructure since their mechanical and technological properties essentially depend on the type and parameters of the microstructure. The technological process of parts production for aerospace applications is multi-operational and consists of deformation, heating and cooling stages. Therefore, it is necessary to simulate the microstructure evolution to obtain high quality parts. In presented paper FE simulation coupled with microstructure evolution during hot forging of TC11 titanium alloy has been performed by QForm FEM code. Constitutive relationships, friction conditions and microstructure evolution model have been established using the experiments. The kinetics of phase transformations has been described by the Johnson-Mehl-Avrami-Kolmogorov (JMAK) phenomenological model. The approach is illustrated by industrial case study that proved its practical applicability and economic advantages for technology development of titanium alloy critical parts.

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