scholarly journals An Analysis Of The Industrial Forging Process Of Flange In Order To Reduce The Weight Of The Input Material

2015 ◽  
Vol 60 (2) ◽  
pp. 849-853 ◽  
Author(s):  
Z. Gronostajski ◽  
M. Hawryluk ◽  
M. Kaszuba ◽  
G. Misiun ◽  
A. Niechajowicz ◽  
...  
Keyword(s):  
Hot Forging ◽  
Industrial Process ◽  
Maximum Load ◽  
Operating Conditions ◽  
Production Costs ◽  
Forging Process ◽  
Die Forging ◽  
Input Material ◽  
Infrared Measurements ◽  
Optimum Direction

Abstract This paper presents an analysis of the industrial process of hot forging a flange. The authors developed several thermomechanical models of the forging process for which they carried out computer simulations using the MSC.Marc 2013 software. In the Jawor Forge flanges with a neck are manufactured by hot forging in crank presses with a maximum load of 25 MN. The input material, in the form of a square bar, is heated up to a temperature of 1150°C and then formed in three operations: upsetting, preliminary die forging and finishing die forging. The main aim of the studies and the numerical analyses, in which the geometry of the tools would be modified, was to maximally reduce the amount of the input material taking into account the capabilities of the Jawor Forge, and consequently to significantly reduce the production costs. Besides the Forge’s equipment resources, the main constraint for modifications was the flange-with-neck forging standard which explicitely defines the tolerances for this element. The studies, which included numerical modelling, infrared measurements and technological tests, consisted in changing the geometry of the tools and that of the forging preform. As a result, the optimum direction for modifications aimed at reducing the mass of the input material was determined. The best of the solutions, making it possible to produce a correct forging in the Jawor Forge operating conditions, were adopted whereby the weight of the preform was reduced by 6.11%. Currently research is underway aimed at the application of the proposed and verified modifications to other flange forgings.

scholarly journals Case Study of the Effect of Precoating on the Decarburization of the Surface Layer of Forged Parts during the Hot Die Forging Process

Materials ◽  
2021 ◽  
Vol 14 (2) ◽  
pp. 422
Author(s):  
Paweł Widomski ◽  
Maciej Zwierzchowski ◽  
Artur Barełkowski ◽  
Mateusz Tympalski
Keyword(s):  
Surface Layer ◽  
Induction Heating ◽  
Hot Forging ◽  
Heating Process ◽  
Forging Process ◽  
Die Forging ◽  
Forged Parts ◽  
Third Stage ◽  
Hot Die Forging

This paper aims to evaluate the effect of pre-coating of forged parts on decarburization in the die forging process. The studies consisted of three stages. In the first instance, different coatings were tested under laboratory conditions by heating steel samples to the temperature of 1200 °C for over five minutes to model the preheating conditions of the induction. Next, testing continued in a commercial forging stand where we tested the effects of different coatings on the rods decarburization during the induction heating process, usually performed before forging. Once completed testing, the measurements and observations of the decarbonized layer were made. The third stage involved analysis of the decarburization of the forged parts after forging. The forged parts were made using precoating of pre-forging elements; pieces cut off a metal rod. Based on tests results, the possibility of using this solution in the technique of industrial hot forging was evaluated. The results of laboratory tests have confirmed that lubrication of metal pieces is sufficient, as well as proved it to be effective in reducing decarburization of the surface layer. Research works conducted in an induction heater showed differences in decarburization depending on a substance and concentration of lubricants that were used. These differences become more apparent when observing the surface layer of the forged parts. Results indicate that decarburization may be reduced to a minimum when we use Bonderite product in a concentration of 66% and 50%. Another lubricant, Berulit 913, may also be used. However, due to burning graphite in high temperatures, reduction of decarburization goes only as far as half of the thickness of the decarbonized layer. Condursal has no significant effect; nevertheless, it protects over the induction heating stage.

FEM Modelling and Experimental Research of Die Forging of Ni-Mo-Fe Alloy Antenna Components

2012 ◽  
Vol 57 (2) ◽  
pp. 627-635 ◽  
Author(s):  
M. Wojtaszek ◽  
P. Chyła ◽  
T. Śleboda ◽  
A. Łukaszek-Sołek ◽  
S. Bednarek
Keyword(s):  
Experimental Research ◽  
Hot Forging ◽  
Fem Simulation ◽  
Impact Testing ◽  
Plastic Properties ◽  
Metallographic Examination ◽  
Forging Process ◽  
Fem Modelling ◽  
Microstructure Observation ◽  
Die Forging

FEM Modelling and Experimental Research of Die Forging of Ni-Mo-Fe Alloy Antenna ComponentsThis work was focused on the design of hot forging process for a selected element of Ni-Mo-Fe alloy. The research included numerical FEM simulation, testing in industrial conditions as well as laboratory tests. The numerical FEM simulation of hot forging of a selected forging was prepared and performed with application of QForm software. Next, the forging tests of the analyzed element were performed in industrial conditions, with application of the parameters used in the numerical simulation. The selected properties of the obtained forging were determined. The metallographic examination was also performed, including microstructure observation as well as the analysis of fractures formed during impact testing of specimens. Chemical composition of the investigated alloy was also examined during SEM-EDS characterization. The results of investigations were compared with the data obtained from FEM simulation, in order to specify the forging process parameters. The research showed, that the parameters of forging of the analyzed alloy assumed in the FEM numerical analysis and then verified in industrial conditions, allowed to produce a good quality product with quite uniform microstructure within its volume. No signs of porosity or micro-shrinkages were observed in the obtained product, what signifies, that the selection of forging parameters for the investigated material allowed to eliminate the casting defects present in the volume of a feedstock. Ni-Mo-Fe alloy product showing the strength and plastic properties allowing its application for the components of antennas was obtained by hot forging.

Sensitivity Analysis of Process Parameters for Developing an Improved Open Die Forging Process

2014 ◽  
Vol 622-623 ◽  
pp. 231-238
Author(s):  
Yu Feng Cheng ◽  
Xiao Guang Yang ◽  
Qi Lu ◽  
Chao Voon Samuel Lim ◽  
Ai Jun Huang
Keyword(s):  
Sensitivity Analysis ◽  
Process Parameters ◽  
Effective Strain ◽  
Hot Forging ◽  
Forging Process ◽  
Analysis Process ◽  
Die Forging ◽  
Experiment Method ◽  
Experimental Process ◽  
Open Die Forging

Open die hot forging has a wide industrial application on deforming ingot into billet with desired dimension and qualified internal microstructure. An example open die forging process of Ti-6Al-4V ingot is selected herein. A 3D FE-based numerical method was used to investigate the open die forging process with respect to the real working conditions. The simulation results were validated by the collected experimental process parameters from the forging system. Moreover, design of experiment method is adopted regarding the variation of process parameters to reveal the effects of critical factors on product deformation and quality characteristics. Results show that the process parameters including press speed, feed and reduction has significant effect on the workpiece deformation and effective strain which represents the forged billet formability and quality. Improved process parameters method is suggested with respect to the experienced benchmark based on the sensitivity analysis. Keywords: Open die forging; Ti-6Al-4V alloy; Sensitivity analysis; Process parameter; Numerical simulation;

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 Advanced Complex Analysis of the Thermal Softening of Nitrided Layers in Tools during Hot Die Forging

Materials ◽  
2021 ◽  
Vol 14 (2) ◽  
pp. 355
Author(s):  
Jakub Krawczyk ◽  
Paweł Widomski ◽  
Marcin Kaszuba
Keyword(s):  
Numerical Modeling ◽  
Surface Layer ◽  
Laboratory Tests ◽  
Complex Analysis ◽  
Nitrided Layer ◽  
Hot Forging ◽  
Thermal Softening ◽  
Effect Of Temperature ◽  
Destructive Effect ◽  
Forging Process

This article is devoted to the issues of thermal softening of materials in the surface layer of forging tools. The research covers numerical modeling of the forging process, laboratory tests of tempering of nitrided layers, and the analysis of tempering of the surface layer of tools in the actual forging process. Numerical modeling was supported by measuring the temperature inside the tools with a thermocouple inserted into the tool to measure the temperature as close to the surface as possible. The modeling results confirmed the possibility of tempering the die material. The results of laboratory tests made it possible to determine the influence of temperature on tempering at different surface layer depths. Numerical analysis and measurement of surface layer microhardness of tools revealed the destructive effect of temperature during forging on the tempering of the nitrided layer and on the material layers located deeper below the nitrided layer. The results have shown that in the hot forging processes carried out in accordance with the adopted technology, the surface layer of working tools is overheated locally to a temperature above 600 °C and tempering occurs. Moreover, overheating effects are visible, because the surface layer is tempered to a depth of 0.3 mm. Finally, such tempering processes lead to a decrease in the die hardness, which causes accelerated wear because of the abrasion and plastic deformation. The nitriding does not protect against the tempering phenomenon, but only delays the material softening process, because tempering occurs in the nitrided layer and in the layers deeper under the nitrided layer. Below the nitrided layer, tempering occurs relatively quickly and a soft layer is formed with a hardness below 400 HV.

Study of the applicability of 22MnB5 sheet metal as protective masks to improve tool life in hot forging process

2020 ◽  
Vol 107 (1-2) ◽  
pp. 39-47
Author(s):  
Luana De Lucca de Costa ◽  
Alberto Moreira Guerreiro Brito ◽  
André Rosiak ◽  
Lirio Schaeffer
Keyword(s):  
Sheet Metal ◽  
Tool Life ◽  
Hot Forging ◽  
Forging Process ◽  
Hot Forging Process

scholarly journals Influence of Anvil Shape of Surface Crack Generation in Large Hot Forging Process

2014 ◽  
Vol 81 ◽  
pp. 480-485 ◽  
Author(s):  
Takefumi Arikawa ◽  
Daisuke Yamabe ◽  
Hideki Kakimoto
Keyword(s):  
Surface Crack ◽  
Hot Forging ◽  
Forging Process ◽  
Crack Generation ◽  
Hot Forging Process
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