scholarly journals Parametric optimization of hot forging process: a six sigma based approach

2021 ◽  
Vol 309 ◽  
pp. 01159
Author(s):  
Kumar Satyam ◽  
Divya Prakash Srivastava ◽  
Saurabh Kumar ◽  
Rajkumar Ohdar
Keyword(s):  
Quality Improvement ◽  
Process Parameters ◽  
Six Sigma ◽  
Hot Forging ◽  
Critical Parameters ◽  
Modern World ◽  
Connecting Rod ◽  
Forging Process ◽  
Forging Die ◽  
Hot Forging Process

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.

Flash Design for Automatic Transfer System of Bearing Hub in Hot Forging Process

2006 ◽  
Vol 116-117 ◽  
pp. 120-123
Author(s):  
Sang Kon Lee ◽  
Hyun Sang Byun ◽  
Byung Min Kim ◽  
Dae Cheol Ko ◽  
C.G. Kang
Keyword(s):  
Numerical Analysis ◽  
Metal Flow ◽  
Hot Forging ◽  
Experimental Results ◽  
Transfer System ◽  
Forging Process ◽  
Hot Forging Die ◽  
Forging Die ◽  
Hot Forging Process ◽  
Forging Load

The aim of this study is to design flash geometry of bearing hub to apply the automatic transfer system in hot forging process. The flash geometry is very important in hot forging process because the flash geometry effects on the metal flow, material losses, forging load, die pressure and so on. In this study, the problem of designing the flash geometry is studied with flash thickness and width considering the maximum die pressure to apply an automatic transfer system in hot forging process for bearing hub. The numerical analysis was conducted by means of the commercial S/W DEFORM. On the basis of numerical analysis the flash geometry of hot forging die was redesigned, and experiment was conducted. From the experimental results, it was possible to produce bearing hub with an automatic transfer system without any deterioration of die lifetime.

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

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.

Effect of Preform Height on Die Wear in Hot Forging Process of Idle Gear by Finite Element Modeling

2017 ◽  
Vol 728 ◽  
pp. 36-41 ◽  
Author(s):  
Panuwat Soranansri ◽  
Mahathep Sukpat ◽  
Taweesak Pornsawangkul ◽  
Pinai Mungsantisuk ◽  
Kumpanat Sirivedin
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Failure Modes ◽  
Hot Forging ◽  
Wear Depth ◽  
Forging Process ◽  
Element Modeling ◽  
Die Wear ◽  
Forging Die ◽  
Hot Forging Process

In hot forging process, the common failure modes of forging die are wear, fatigue fracture and plastic deformation. Normally die wear is occurred the most frequently and it influents directly to shape, dimension and surface quality of product. For this research, the hot forging process of idle gear was studied to focus on die wear. This product is forged in three steps. There are preform step, rougher step and finisher step. Height of preform shape in preform step was a parameter to study effect on die wear. Archard’s wear model in finite element modeling was used to predict die wear. The finite element modeling was verified by real hot forging process for reliable model and then it was used to determine the optimum preform height to reduce die wear. Finally the result showed that the maximum wear depth on the forging die was reduced 41.2% from original industry process.

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

2012 ◽  
Vol 47 (8) ◽  
pp. 3837-3848 ◽  
Author(s):  
J. W. Qiu ◽  
Y. Liu ◽  
B. Liu ◽  
Y. B. Liu ◽  
B. Wang ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Process Parameters ◽  
Hot Forging ◽  
Forging Process ◽  
Hot Forging Process

One-Step Gradual Forging Process by Using Direct Heating Billet within Die

2015 ◽  
Vol 764-765 ◽  
pp. 122-126
Author(s):  
Fang Sung Cheng ◽  
Yu Shun Cheng
Keyword(s):  
Hot Forging ◽  
High Strength ◽  
Experimental Result ◽  
Forging Process ◽  
Direct Heating ◽  
Gradual Deformation ◽  
One Step ◽  
Strength Material ◽  
Forging Die ◽  
Hot Forging Process

Direct heating billet within a die by using resistance heating method was developed to form the high strength material in one-step gradual forging process. During the forging process, the pressing speed of the upper die is controlled with the pace of the heating billet. In the proposed method, the forging die can be used as both the forming and heating of the billet. Based on this innovative forming method, experimental result shows that the billet could be heated quickly to 1000oC in about 5 seconds and the high strength material was successfully formed to the shape of bolt head in one-step gradual forging process. With the proposed mechanism, the rapidly heating and gradual deformation during the hot forging process can be successfully carried out.

Optimizing Hot Forging Process Parameters of Hollow Parts Using Tubular and Cylindrical Workpiece: Numerical Analysis and Experimental Validation

2018 ◽  
Vol 8 (2) ◽  
Author(s):  
Angela Selau Marques ◽  
Luana De Lucca de Costa ◽  
Rafael Luciano Dalcin ◽  
Alberto Moreira Guerreiro Brito ◽  
Lirio Schaeffer ◽  
...  
Keyword(s):  
Numerical Analysis ◽  
Process Parameters ◽  
Experimental Validation ◽  
Hot Forging ◽  
Forging Process ◽  
Cylindrical Workpiece ◽  
Hot Forging Process

Direct Heating Billet within Die during Hot Forging Process

2013 ◽  
Vol 479-480 ◽  
pp. 25-29 ◽  
Author(s):  
Fang Sung Cheng ◽  
Yu Shun Cheng
Keyword(s):  
Hot Forging ◽  
High Strength ◽  
Heating System ◽  
Heating Time ◽  
Resistance Heating ◽  
Heating Efficiency ◽  
Forging Process ◽  
Direct Heating ◽  
Forging Die ◽  
Hot Forging Process

This paper reports a simple and effective method to increase heating efficiency and decrease heating time that renders direct heating billet within die using resistance heating system during hot forging process. The apparatus employs resistance equipment set into the forging die, and the billet was directly resistance heating by the forging die. Base on the approach, the die as a forming condition on direct heating and forging was also researched. The result of experiments shows that the billet could be heated quickly to 1000°C in about 5 seconds and the high strength material (AISI4140) was successfully formed to the shape of bolt head. With this mechanism, the rapidly heating and isothermal deformation during the hot forging process can be achieved.

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