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.

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

2020 ◽  
Author(s):  
Paweł Widomski ◽  
Maciej Zwierzchowski ◽  
Artur Barełkowski ◽  
Mateusz Tympalski
Keyword(s):  
Surface Layer ◽  
High Temperatures ◽  
Induction Heating ◽  
Laboratory Tests ◽  
Hot Forging ◽  
Forging Process ◽  
Induction Heater ◽  
Forged Parts ◽  
Hot Die Forging

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.

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.

FEM Analysis for Tangible Component Production

2014 ◽  
Vol 611-612 ◽  
pp. 1657-1664 ◽  
Author(s):  
Mario Rosso ◽  
Ildiko Peter
Keyword(s):  
Material Flow ◽  
Hot Forging ◽  
Fem Analysis ◽  
Forging Process ◽  
Die Life ◽  
One Step ◽  
Hot Forging Process

In high temperature metal forming techniques, analysis of the material flow and deformation as well as wear distribution during forging are very important, because they are directly correlated to the quality of the final component and to the productivity and die life. In this paper a commercially available Finite Element Method based simulator, namely Transvalor Forge 2008©, is used to numerically investigate on the effects of the various parameters on the mode of the failure of dies during hot forging. The exploration has the purpose to evaluate the possibility and related benefits of the advancement from a traditional hot forging process to a modern thixoforging one in the case study of steel-made steering pistons production. As a first step, the part related to the hot forging process is in detailed analyzed, in order to get an exhaustive description of the role of the different parameters. One step and two step solutions are proposed and discussed.

One Action Press Forming of Helix Bevel Gear by Using Multi-Cylinder Press and Die Heating System

2018 ◽  
Vol 12 (5) ◽  
pp. 767-774
Author(s):  
Katsuaki Nakamura ◽  
◽  
Hiroshi Koresawa ◽  
Hiroyuki Narahara
Keyword(s):  
Hot Forging ◽  
High Hardness ◽  
Heating System ◽  
Bevel Gear ◽  
Cold Forging ◽  
Machining Time ◽  
Forging Process ◽  
Forged Parts ◽  
Almost All ◽  
Forging Press

In the case of a complex shaped helix bevel gear, the forging of complete gear tips is very difficult to achieve. In almost all cases, tooth profile is finished by cutting machine from simple shaped forged parts, therefore requiring considerable machining time and cost. However, there are many approaches to forging. Forging is mainly classified as hot and cold forging, and uses a single motion press. In the case of hot forging takeoff of products from die is difficult by the cooling shrinkage from die and accuracy of products is lower level than cold forging. In addition, in the case of cold forging, a complicated shape is difficult to achieve based on the lack of ductility of the materials. To realize a helix bevel gear using a single forging operation, we applied a tool heating system and three-axis forging press. The tool heating system is applied to prevent a temperature decrease in the material by contact between the tool and forging material during the forging process. Further, to optimize the forging direction and timing, we used a three-axis forging press. We confirmed good forging capability of this special forging process, as well as the high precision of the forged parts. Moreover, through the thermo-mechanical control of steel and the tool temperature, the forged parts showed good mechanical properties, such as high hardness.

Numerical Simulation of Hot Die Forging Process of Ti-6Al-4V Alloy Blade

2017 ◽  
Vol 898 ◽  
pp. 1325-1331 ◽  
Author(s):  
Jia Hao Chen ◽  
Jin Shan Li ◽  
Bin Tang ◽  
Li Hua Du ◽  
Hong Chao Kou
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Stress Distribution ◽  
Strain Distribution ◽  
3D Finite Element ◽  
Forging Process ◽  
Die Forging ◽  
3D Finite Element Method ◽  
Deformation Area ◽  
Hot Die Forging

Ti-6Al-4V alloy is used extensively in aerospace industries due to its excellent properties. In this paper, the hot die forging process of the Ti-6Al-4V alloy blade was simulated by using 3D finite element method. Based on the model, the effect of process parameters on the deformation was investigated. The results show that the increase of temperature is beneficial to improving the uniformity of stress distribution. The slower the declining velocity of upper die is, the larger the strain gradient of severe deformation area will be. In addition, the stress distribution gets uniform with velocity decreasing. The large friction coefficient can make strain distribution uneven and cause symmetry of stress distribution. The proposed numerical simulation of hot die forging of blade in the present work may yield important information for the development of hot die forging techniques and the manufacture of blade.

Laboratory and Performance Studies of Anti-wear Coatings Deposited on Nitrided Surfaces of Tools used in an Industrial Hot Die Forging Process

2017 ◽  
Vol 26 (6) ◽  
pp. 2798-2813 ◽  
Author(s):  
Marek Hawryluk ◽  
Paweł Widomski ◽  
Jerzy Smolik ◽  
Marcin Kaszuba ◽  
Jacek Ziemba ◽  
...  
Keyword(s):  
Performance Studies ◽  
Forging Process ◽  
Die Forging ◽  
And Performance ◽  
Wear Coatings ◽  
Hot Die Forging

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.

Simulation and Microstructure Predict during Hot Die-Forging of Cast Mg-7.0Al-0.2Zn Magnesium Alloy

2010 ◽  
Vol 152-153 ◽  
pp. 1293-1296
Author(s):  
Li Hong Wu
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Magnesium Alloy ◽  
Strain Distribution ◽  
Forging Process ◽  
Die Forging ◽  
Comparison Results ◽  
Hot Die Forging ◽  
Good Agreement

Employing the dies for aluminum alloy parts, the hot die-forging forming and numerical simulation of semi-continuous casting Mg-7.0Al-0.4Zn (AZ70) were carried out. It was indicated that AZ70 has a worse fluidity during forging and is consequently difficult to fill fully compared to aluminum alloys. The microstructure of the AZ70 forgings is in good agreement with the strain distribution generated by simulation, and strain distribution can predict the microstructure evolution. The comparison results can give a guideline on developing forging process and controlling forgings quality of the AZ70 alloy.

Investigation on Heat Transfer and Its Effect on Titanium Hot Forging Process

2008 ◽  
Author(s):  
K. Davami ◽  
M. Shaygan ◽  
M. K. Besharaty ◽  
A. Mellat ◽  
B. Serajzadeh
Keyword(s):  
Heat Transfer ◽  
Strain Rate ◽  
Cooling Rate ◽  
Hot Forging ◽  
Turbine Disk ◽  
Two Dimensional ◽  
Fem Model ◽  
Die Forging ◽  
Hot Die Forging ◽  
Selection Of

Titanium forged components have been widely used in aircraft engine industry because of their superior specific strength to weight ratio at high temperature. Turbine disk is one of the most demanding forging parts. The flow stress of titanium alloy Ti-6Al-4V is strongly dependent on temperature and strain rate during hot forging. The cooling rate can be designed to manage the temperature profile of dies by distinct spray setup. The workpiece loses heat to die by contact when getting heat up for deformation. The study aims to assess the influence of the discrete cooling rate and interfacial contact heat transfer on the optimum plastic deformation and the optimum die life for a Ti-6Al-4V hot-die forging. A two-dimensional FEM model of titanium turbine disk is employed to study the mechanical and thermal interaction between the hot dies and the workpiece. After hundreds of runs of the forging cycles thermal-steady state is built up and the thermal-steady simulation is considered to reflect the actual production situation. The development of different microstructure and phase compositions in various regions of workpiece is the result of the high sensitivity of two-phase TI-6Al-4V to strain and temperature of plastic deformation. Proper selection of these parameters allows one to control its mechanical properties and avoid deformation failure. Providing the productivity and economic demands, thermal design is a more manageable way than strain rate control for hot die forging. Microstructure control and uniformity of deformation can be achieved through the selection of optimum processing conditions with the aid of processing maps. This research focuses on the effects of forging interfacial heat transfer coefficient and discrete cooling rate along tool cavity when other processes parameters such as strain rate and cycle time given fixed. The temperature control will help achieve a good balance among strength, ductility and fracture toughness. The flow stability, load and energy, die wear, and die tempering and chilling are investigated for a turbine disk hot-die forging using a two-dimensional FEM model.

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