scholarly journals DESTRUCTION OF THE BILLET MATERIAL DURING PLANING.

2020 ◽  
Vol 83 (03) ◽  
pp. 34-38
Author(s):  
Denis Chemezov ◽  
◽  
Emil Akhmetov ◽  
Vasiliy Semenov ◽  
Ilya Filippov ◽  
...  
Keyword(s):  
Billet Material

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.

Combined Extrusion-Forging: Simulation, Experimental and Microscopic Investigation of Axisymmetric Single Collar Collet Chuck Holder

2017 ◽  
Author(s):  
Srikar Potnuru ◽  
Susanta K. Sahoo ◽  
Santosh K. Sahoo
Keyword(s):  
Flow Pattern ◽  
Metal Flow ◽  
Numerical Data ◽  
Microscopic Investigation ◽  
Context Processing ◽  
Fine Grained ◽  
Forming Load ◽  
Billet Material ◽  
Heavy Loads ◽  
Structural Validation

Combined Extrusion-Forging process is a renowned metal forming method which serves as a pathway for manufacturing components of complex design. In that context processing a component with better mechanical and metallurgical properties can be enhanced by severe plastic deformation which processes the fine-grained materials formation in the product. These fine-grained materials achieved by SPD makes the component with superior quality. The novelty of the concept is to validate the presence of fine-grained materials at lower ram displacement. This paper presents the estimated forming load, metal flow pattern and alike, using aluminum 1072 as billet material for manufacturing SCCCH, along with micro-structural validation by experimental die-punch setup and simulation using modelling software DEFORM3D. Numerical analysis was also performed to estimate the forming load and metal flow patterns. Good number of experiments has been carried out at various punch movements to find out forming load and metal flow pattern. Microscopic analyses have been performed to validate the data with the results obtained from the experimentation. It was found that the numerical data was well validated with the experimental results. Further, Micro-hardness analysis was also performed. As the component was manufactured on application of heavy loads, the residual stress was also found to check the load carrying capacity of the component.

Evaluation of ASME Pressure Vessel Code Prohibitions on Rod and Bar Stock and Potential Remedies

2014 ◽  
Author(s):  
John J. Aumuller ◽  
Vincent A. Carucci
Keyword(s):  
Pressure Vessels ◽  
Early 20Th Century ◽  
Economic Disadvantage ◽  
User Experiences ◽  
The Public ◽  
Division 1 ◽  
Asme Code ◽  
Billet Material ◽  
Section Viii ◽  
Division 2

The ASME Codes and referenced standards provide industry and the public the necessary rules and guidance for the design, fabrication, inspection and pressure testing of pressure equipment. Codes and standards evolve as the underlying technologies, analytical capabilities, materials and joining methods or experiences of designers improve; sometimes competitive pressures may be a consideration. As an illustration, the design margin for unfired pressure vessels has decreased from 5:1 in the earliest ASME Code edition of the early 20th century to the present day margin of 3.5:1 in Section VIII Division 1. Design by analysis methods allow designers to use a 2.4:1 margin for Section VIII Division 2 pressure vessels. Code prohibitions are meant to prevent unsafe use of materials, design methods or fabrication details. Codes also allow the use of designs that have proven themselves in service in so much as they are consistent with mandatory requirements and prohibitions of the Codes. The Codes advise users that not all aspects of construction activities are addressed and these should not be considered prohibited. Where prohibitions are specified, it may not be readily apparent why these prohibitions are specified. The use of “forged bar stock” is an example where use in pressure vessels and for certain components is prohibited by Codes and standards. This paper examines the possible motive for applying this prohibition and whether there is continued technical merit in this prohibition, as presently defined. A potential reason for relaxing this prohibition is that current manufacturing quality and inspection methods may render a general prohibition overly conservative. A recommendation is made to better define the prohibition using a more measurable approach so that higher quality forged billets may be used for a wider range and size of pressure components. Jurisdictions with a regulatory authority may find that the authority is rigorous and literal in applying Code provisions and prohibitions can be particularly difficult to accept when the underlying engineering principles are opaque. This puts designers and users in these jurisdictions at a technical and economic disadvantage. This paper reviews the possible engineering considerations motivating these Code and standard prohibitions and proposes modifications to allow wider Code use of “high quality” forged billet material to reflect some user experiences.

Quantitative Comparison Between Precision Closed-Die Forging-Force Data and Computer Simulations

1992 ◽  
Vol 114 (4) ◽  
pp. 465-471 ◽  
Author(s):  
J. N. Majerus ◽  
K. P. Jen ◽  
H. Gong
Keyword(s):  
Cross Section ◽  
Quantitative Comparison ◽  
Elastic Behavior ◽  
Material Parameters ◽  
Closed Die Forging ◽  
Billet Material ◽  
Forging Force ◽  
Force Data ◽  
Significant Data ◽  
Good Agreement

This paper presents a study of precision closed-die, isothermal, forgings via both experiments and computer simulation. The closed-die cross-section was an “H” shape and Tin/Lead eutectic solder was used for the billet material. Extensive statistical analysis of the axial force versus displacement history was conducted using replicated forging experiments. The purpose of the experiment was to obtain statistically significant data so that accuracy tests could be conducted on different FEM computer models, e.g., ALPID, EPIC2D, NIKE2D, and DYNA2D. Overall, the forging history exhibited complex behavior consisting of five distinct regions. The experimental results yield a 5.2 percent COV in the required forging force for a specific top-die displacement. A 6.5 percent COV in the “stiffness” of the first region (elastic behavior) of the forging history was also obtained. One set of simulations with one FEM computer model, ALPID Version 2.1 for rigid-thermoviscoplastic behavior, was conducted. The occurrence of all four viscoplasticflow regions was qualitatively predicted by the simulations. Quantitatively, the simulations are within the experimental bounds for the early viscoplastic regions, but out of bounds for the later regions. It appears that, for the eutectic tin/lead billet material, there is no combination of “power-law” material parameters that yield good agreement with the later stages of the forging force history.

scholarly journals Variation assessment of yield mode at pressure welding

2021 ◽  
Vol 2021 (3) ◽  
pp. 16-18
Author(s):  
Vladimir Chudin ◽  
Valeriy Platonov ◽  
Pavel Romanov
Keyword(s):  
Power Method ◽  
Pressure Welding ◽  
Billet Material ◽  
Variation Assessment ◽  
Yield Mode

There are offered ratios for the computation of deformation and power modes of yielding at billet pressure welding. A power method is used for the computation of pressure with reference to a flat discontinuous field of movement speeds. Pressure minimization is carried out in a variation way. The assessment of billet material damageability is shown.

scholarly journals Development of an Aluminum-Based Hybrid Billet Material for the Process-Integrated Foaming of Hollow Co-Extrusions

Metals ◽  
2021 ◽  
Vol 11 (9) ◽  
pp. 1382
Author(s):  
Florian Patrick Schäfke ◽  
Susanne Elisabeth Thürer ◽  
Hans Jürgen Maier ◽  
Christian Klose
Keyword(s):  
Adhesive Bond ◽  
Extrusion Process ◽  
High Energy ◽  
Scanning Calorimetry ◽  
Foaming Agent ◽  
Process Route ◽  
Precursor Material ◽  
Foaming Behavior ◽  
Billet Material ◽  
High Energy Absorption

Metal foams are attractive for lightweight construction in the automotive sector since they provide high-energy absorption and good damping properties, which is crucial, e.g., for crash structures. Currently, however, foams are produced separately and then pasted into the components. Consequently, the overall mechanical properties depend significantly on the quality of the adhesive bond between the foam and the structural component. A new process route for the manufacture of hybrid foamed hollow aluminum profiles is proposed. In this approach, a foamable precursor material is directly integrated into the extrusion process of the hollow structural profile. To this end, special low-melting alloys were developed in this study to enable foaming inside the aluminum profile. The melting intervals of these alloys were examined using differential scanning calorimetry. One of the promising AlZnSi alloys was atomized, mixed with a foaming agent and then compacted into semi-finished products for subsequent co-extrusion. The foaming behavior, which was investigated by means of X-ray microscopy, is shown to depend primarily on the mass fraction of the foaming agent as well as the heat treatment parameters. The results demonstrate that both the melting interval and the foaming behavior of AlZn22Si6 make this particular alloy a suitable candidate for the desired process chain.

Application of Appropriate Coatings on Extrusion Dies and Evaluation of Their Performance During Hot Extrusion of Aluminum

2010 ◽  
Author(s):  
Antonios Lontos ◽  
George Demosthenous ◽  
Filippos Soukatzidis
Keyword(s):  
Hot Extrusion ◽  
Experimental Tests ◽  
Working Life ◽  
Element Model ◽  
Extrusion Process ◽  
Extrusion Speed ◽  
Coating Materials ◽  
Extrusion Dies ◽  
Billet Material ◽  
Aluminum Material

The aim of this paper is to study the effect of extrusion parameters (extrusion speed and temperature), die geometry, and the application of appropriate coating materials on the extrusion dies in order to extend their working life. To achieve the above goal FEM techniques and experimental tests adopted and simulating and experimental results evaluated. In this way, special FEM software was used to set up the finite element model of the aluminum extrusion. As a billet material the 6061 aluminum was used, with a specific diameter and length. The extrusion process was modeled as isothermal, which means that the billet material preheated at the specific temperature and then it was pressured into the two different dies, with a specific extrusion ratio. The extrusion speed was varied between 0.5 to 1 mm/sec and the extrusion temperature varied between 400 °C to 500 °C. The extrusion angle of the two different dies was 9° degrees. The fillet radius at the top surfaces was selected to be 1 mm. The friction between aluminum material (billet) and the extrusion equipment was i) aluminum material and die 0.3, ii) aluminum material and ram 0.9 and iii) aluminum material and container equal to 0.96. Optimized algorithms of extrusion parameters were proposed regarding to the concluded simulating results. The results obtain from the simulation procedure help to the better understanding of the specific extrusion process, leading to better modification of the experimental procedure. In this way, experimental tests were conducted on special laboratory extrusion press using the two different die geometries coated with three different PVD coatings. By means of these experimental tests the additional working life of the coated dies, during hot extrusion process, was able to be evaluated. In addition, the three different coatings where tested by established quality procedures in order to determine their behavior on the material of the extrusion die.

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