Analysis of a new process of forging a 2017A aluminium alloy connecting rod

2021 ◽  
pp. 1-32
Author(s):  
Grzegorz Winiarski ◽  
Anna Dziubinska
Keyword(s):  
Aluminium Alloy ◽  
The Finite Element Method ◽  
Connecting Rod ◽  
Sand Cast ◽  
Input Material ◽  
Lower Strain ◽  
New Process ◽  
Billet Material ◽  
Hammer Forging ◽  
Deform 3D

Abstract The paper presents the results of a theoretical analysis of a new process of hammer forging of a connecting rod and the technology currently used. In the industry at present connecting rods are forged from extruded rods. The new forging technology assumes the use of a billet in the form of a cast preform. For the calculations, it has been assumed that the billet material will be a Ø30 x 148 mm rod and a cast preform. Two variants of preforms have been modelled, from which products of the assumed geometry with different degree of strain are obtained. Calculations were made using the finite element method in the Deform 3D program. The input material was 2017A aluminium alloy in the form of rods and sand cast preforms. On the basis of the conducted research it was found that the use of cast preforms reduces material waste by about 80% in relation to the technology of forging from the bar, and reduces the energy consumption of the process by about 75%. Both geometrical variants of the forging preforms ensure obtaining a forging with the assumed shape and dimensions, although forging from the forging preform with a smaller degree of strain seems to be a safer variant in terms of the possibility of cracking of the material. This is supported by the lower strain and Cockcroft-Latham integral values.

scholarly journals Theoretical and Experimental Analysis of a New Process for Forming Flanges on Hollow Parts

Materials ◽  
2020 ◽  
Vol 13 (18) ◽  
pp. 4088
Author(s):  
Grzegorz Winiarski ◽  
Andrzej Gontarz ◽  
Grzegorz Samołyk
Keyword(s):  
Software Package ◽  
Large Diameter ◽  
Testing Machine ◽  
Experimental Tests ◽  
New Method ◽  
The Finite Element Method ◽  
New Process ◽  
3D Software ◽  
Deform 3D ◽  
Extrusion Method

The paper presented a new method for forming flanges on hollow parts by incremental radial extrusion. In the classic process of radial extrusion, additional rings were used to limit the free flow of material in the radial direction. The flange was formed progressively, using rings of increasing diameters. The proposed method was verified by numerical analysis and experimental tests. The numerical calculations were performed by the finite element method using the Deform-3D software package. Tubes made of aluminum alloy EN AW 6060 were used as billets. Laboratory tests were carried out using the Instron 1000 HDX testing machine. The objective of the study was to determine the validity of the proposed flange extrusion method. Results demonstrated that the new method made it possible to produce flanges with a relatively large diameter and uniform thickness, confirming the effectiveness of the proposed forming technique.

Investigation on Elliptic-Shaped Flaring Process of Metal Tube with Finite Element Method

2007 ◽  
Vol 364-366 ◽  
pp. 949-954 ◽  
Author(s):  
Chin Tarn Kwan
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Tube Wall ◽  
The Finite Element Method ◽  
Influence Of Process Parameters ◽  
Tube Wall Thickness ◽  
Billet Material ◽  
Tube Flaring ◽  
Deform 3D ◽  
Element Method

In this study, the finite element method was used to investigate the cold elliptic-shaped flaring process of metal tubes with a conical punch from a tube billet. A series of simulations on tube flaring was carried out using the FEM program DEFORM 3D. The influence of process parameters such as tube wall thickness, punch conical length, aspect ratio of elliptic shape, friction factor, punch fillet radius and strength coefficient of the billet material on the critical flaring ratio of the tube were analyzed.

Die Forging Process Simulation of a Connecting Rod

2011 ◽  
Vol 704-705 ◽  
pp. 302-307
Author(s):  
Lei Xu ◽  
Guang Ze Dai ◽  
Xing Ming Huang ◽  
Jing Han ◽  
Jun Wen Zhao
Keyword(s):  
Reduction Rate ◽  
Temperature Fields ◽  
Stress Fields ◽  
Connecting Rod ◽  
Preheat Temperature ◽  
Forging Process ◽  
Optimum Parameters ◽  
Die Forging ◽  
High Level ◽  
Deform 3D

Numerical simulation of connecting rod die forging processing was performed by finite element method (FEM) software Deform 3D. The changes of the temperature fields, stress fields of the billet and dies, and upper setting force-stroke curve during the die forging were obtained. The simulation results show that (1) the increase of the fillet radius of dies could effectively reduce the stress concentration so that to prevent the die crack arising at high level stress; (2) the optimum parameters of die forging process are 430°C for forging temperature, 200°C for preheat temperature of dies and 80mm/s for reduction rate by comparing both fields of the stress and temperature during different forging process..

scholarly journals Effects of Hard Surface Grinding and Activation on Electroless-Nickel Plating on Cast Aluminium Alloy Substrates

2014 ◽  
Vol 2014 ◽  
pp. 1-10 ◽  
Author(s):  
Olawale Olarewaju Ajibola ◽  
Daniel T. Oloruntoba ◽  
Benjamin O. Adewuyi
Keyword(s):  
Aluminium Alloy ◽  
Electroless Nickel ◽  
Sodium Hypophosphite ◽  
Palladium Chloride ◽  
Alloy Sample ◽  
Sand Cast ◽  
Hard Surface ◽  
Cast Aluminium ◽  
Surface Polishing ◽  
Cylinder Piston

This work examined effects of hard surface polishing grits and activation on electroless-nickel (EN) plating on cast aluminium alloy substrates in sodium hypophosphite baths. As-received aluminium alloy sample sourced from automobile hydraulic brake master cylinder piston was melted in electric furnace and sand cast into rod. The cast samples were polished using different grits (60 μm–1200 μm) before plating. The effects on adhesion, appearance, and quantity of EN deposits on substrates were studied. Observation shows that the quantity of EN deposit is partly dependent on the alloy type and roughness of the surface of the substrates, whereas the adhesion and brightness are not solely controlled by the degree of surface polishing. The best yield in terms of adhesion and appearance was obtained from the activation in zincate and palladium chloride solutions. Higher plating rates (g/mm2/min) of 3.01E-05, 2.41E-05, and 2.90E-05 were obtained from chromate, zincate, and chloride than 8.49E-06, 8.86E-06, and 1.69E-05 as obtained from HCl etched, NaOH, and H2O activated surfaces, respectively.

Improving the honing accuracy of the holes of stepped thin-walled cylinders

2021 ◽  
pp. 49-54
Author(s):  
V.A. Ogorodov
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cutting Forces ◽  
Software Package ◽  
The Finite Element Method ◽  
Radial Forces ◽  
Thin Walled ◽  
Hole Machining ◽  
Deform 3D ◽  
Walled Cylinder

Different ways of fixing of stepped thin-walled cylinders during honing are analyzed. The conditions for increasing the accuracy of hole machining are determined on the basis of unevenness of cylinder deformations from clamping forces and radial forces simulating cutting forces. The studies used the finite element method and the DEFORM-3D V6.1 software package. Keywords: honing, stepped thin-walled cylinder, hole, accuracy, fixing method, deformation, unevenness, DEFORM-3D V6.1 software package. [email protected]

Claw-Pole Closed Forging Process

2014 ◽  
Vol 912-914 ◽  
pp. 605-608 ◽  
Author(s):  
Xuan Rong Xin ◽  
Ding Xu ◽  
Cheng Song He ◽  
Xin Cheng Liu
Keyword(s):  
Mass Production ◽  
New Technology ◽  
Extrusion Process ◽  
Forming Force ◽  
Short Life ◽  
Forging Process ◽  
New Process ◽  
Corner Filling ◽  
Hot Die Forging ◽  
Deform 3D

Aimed at the present domestic problems in the forging process of claw pole, such as insufficient corner filling, excessive forming force and short life of dies. On the basis of the analyzing in the claw pole, a new process named the closed hot die forging, direct extrusion process of claw pole is constituted. The numerical simulation using DEFORM-3D and the special mould are used in the forging experiment in order to check the new process. The results show that, new technology has greatly reduced the forming force, thereby reducing the production processes and improving the life of dies for mass production.

An Innovative Compression Mold Design for Manufacture of Reel Mower Helical Blades

2016 ◽  
Vol 851 ◽  
pp. 255-258
Author(s):  
Chung Ming Tan ◽  
Gin Yei Lin
Keyword(s):  
Computer Aided Engineering ◽  
Roll Forming ◽  
Forming Process ◽  
Compression Process ◽  
New Process ◽  
Computer Aided ◽  
Potential Applications ◽  
Actual Design ◽  
Roll Forming Process ◽  
Deform 3D

This research is focused on the helical blades used in the reel mower machine which uses 5 to 10 helical blades. These blades are normally manufactured using the roll forming process which has certain demerits. This research is done to develop a new process known as compression process for the manufacture of blades using computer aided engineering. To save cost, time as well as waste of material the computerized simulation process is being used. The design of the blade and the die for the compression and modification are done using software SolidWorks. Simulation is performed using software DEFORM-3D. The simulation result and the actual design are compared using software Geomagic. This study also shows the potential applications of computer aided engineering and its benefits in verifying and reinventing the part manufacturing process.

Investigation of the Hammer Forging Process of Large-Sized Turbine Blades of Stainless Steel

2019 ◽  
Vol 822 ◽  
pp. 150-158 ◽  
Author(s):  
Maksim Olegovich Smirnov ◽  
Tatiana Alexandrovna Chizhik ◽  
Alexandr Maksimovich Zolotov
Keyword(s):  
Stainless Steel ◽  
Turbine Blades ◽  
Process Data ◽  
Influence Of Process Parameters ◽  
Forging Process ◽  
Forming Temperature ◽  
Experimental Process ◽  
Deformation Modes ◽  
Hammer Forging ◽  
Deform 3D

Investigations of the rheological properties and the formation of the structure of stainless steel were performed. A computer model of the process of hammer forging of the turbine blades made of stainless steel 1.3 m long in the package Deform-3D was developed , with the help of which the necessary coefficients and parameters are determined to ensure maximum convergence of the calculated and experimental process data. The obtained data were used to create a mathematical model for stamping a large-sized turbine blade made of stainless steel with a length of 2.1 m. Mathematical modeling of the processes of stamping and distorting of a large-sized blade in the software package Deform-3D has been performed. The influence of process parameters on the stress-strain state (SSS), forming, temperature field in the forging at various stages of stamping. Determined temperature and deformation modes of stamping, the need for additional heating and optimal forgings geometry by stamping.

Analysis of Strain Hardening Behaviour of Cast Aluminium Alloy 354 Subjected to Artificial Ageing at Various Temperatures

2013 ◽  
Vol 856 ◽  
pp. 231-235 ◽  
Author(s):  
Aditya Eswar ◽  
Arnav Gupta ◽  
G. Dinesh Babu ◽  
M. Nageswara Rao
Keyword(s):  
Heat Treatment ◽  
Aluminium Alloy ◽  
Strain Hardening ◽  
Automotive Industry ◽  
Mechanical Behaviour ◽  
Artificial Ageing ◽  
Cast Aluminium ◽  
Heat Treated ◽  
Lower Strain ◽  
Wide Scale

Automotive industry makes wide scale use of cast aluminium alloy 354 in the production of crucial components, such as compressor wheels for turbochargers. The compressor wheels undergo T61 heat treatment, involving artificial ageing at 188°C. This study focuses on the possible improvement of the mechanical behaviour of the components by subjecting them to modified heat treatments involving usage of lower artificial ageing temperatures (160, 171 and 177°C). A comparative analysis of tensile properties and strain hardening behaviour has been carried out with different artificial ageing temperatures. Results showed that the heat treatment routinely employed by the industry (aged at 188°C) leads to overageing, thereby resulting in relatively inferior mechanical properties and lower strain hardening rates as compared to the samples heat treated at lower artificial ageing temperatures. It is concluded that lowering of the artificial ageing temperature can lead to a superior state of components with respect to mechanical behaviour.

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