Improvement in quality of waveguide fl anges made of AK12 (AL2) alloy obtained by liquid forging method

2020 ◽  
pp. 291-294
Author(s):  
P.A. Golovkin
Keyword(s):  
Forging Process ◽  
Superheat Temperature

The liquid forging process of typical fl ange of antenna waveguide is analyzed. It is shown that decrease in the superheat temperature reduces the number and size of gas pores and the depth of ring seals in the casting of the fl ange, and improves its structure.

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.

Study of Isothermal Split-Die Precision Forging Process of High-Strength Aluminum Alloy Complex-Shape Forgings

2014 ◽  
Vol 941-944 ◽  
pp. 1761-1768
Author(s):  
Jun Lin ◽  
Feng Kang ◽  
Chuan Kai Hu ◽  
Qiang Chen ◽  
Zu De Zhao
Keyword(s):  
Complex Shape ◽  
Dimensional Accuracy ◽  
High Strength ◽  
Hydraulic Press ◽  
Geometric Configuration ◽  
Forging Process ◽  
Precision Forging ◽  
Die Forging ◽  
Calculation Results

Taking the geometric configuration of complex-shape forging into account, the isothermal split-die forging method, which is one multi-way die forging technology and can be operated on the general hydraulic press, is employed. The temperatures of billed and dies are 420°C and 380°C in the isothermal forging process. The coupled thermo-mechanical finite element method (FEM) is used to analyze the forging process. FEM calculation results show several folds had been formed in the final forging process due to unreasonable geometric configuration of preform. The folds mechanism is that direction of velocities become cross on the surface of billet, and the folds can be avoided if the direction would be kept convex. And then the preform is redesigned. A set of isothermal precision forming equipment is designed and manufactured. The experimental results verify the selected process and preform configuration. And all of the hardness, dimensional accuracy and surface quality of the forgings obtained by the equipments satisfy the requirements.

Methodology for Modelling Diffusion Bonding in Powder Forging

2016 ◽  
Vol 716 ◽  
pp. 817-823
Author(s):  
Yi Wang ◽  
Idris K. Mohammed ◽  
Daniel S. Balint
Keyword(s):  
Process Parameters ◽  
Diffusion Bonding ◽  
Bonding Process ◽  
Volume Element ◽  
Particle Packing ◽  
Forging Process ◽  
Forming Load ◽  
Temperature Load ◽  
Powder Particles

Interfacial bonding has a significant influence on the quality of processed components formed by powder forging. Consequently, modelling the bonding process is important for controlling the condition of the components and predicting optimum forging process parameters (e.g. forming load, temperature, load-holding time, etc.). A numerical model was developed in the present work to simulate diffusion bonding (DB) during the direct powder forging (DF) process. A set of analytical equations was derived and implemented in the finite element (FE) software Abaqus via a user-defined subroutine. The DB model was validated using a two-hemisphere compression simulation. The numerical results demonstrated that the DB model has the ability to: 1) determine the bonding status between powder particles during the forging process, and 2) predict the optimum value for key powder forging process parameters. The DB model was also implemented in a representative volume element (RVE) model which was developed in an earlier work to simulate the powder forging process by considering particle packing and thermo-mechanical effects.

scholarly journals Application of a Prototype Thermoplastic Treatment Line in Order to Design a Thermal Treatment Process of Forgings with the Use of the Heat from the Forging Process

Materials ◽  
2020 ◽  
Vol 13 (11) ◽  
pp. 2441
Author(s):  
Marek Hawryluk ◽  
Zbigniew Gronostajski ◽  
Maciej Zwierzchowski ◽  
Paweł Jabłoński ◽  
Artur Barełkowski ◽  
...  
Keyword(s):  
Thermal Treatment ◽  
Production Costs ◽  
Thermal Treatments ◽  
Controlled Cooling ◽  
Repeated Heating ◽  
Forging Process ◽  
Motor Industry ◽  
Energy Consuming ◽  
Time And Energy

The global production of die forgings is an important branch of the motor industry for obvious reasons, resulting from the very good mechanical properties of the forged products. The expectations of the recipients, beside the implementation of the forging process, include also a range of supplementary procedures, such as finishing treatment including shot blasting, thermal treatment, and machining, in order to ensure the proper quality of the provided semi-product or the ready detail for the assembly line. Especially important in the aspect of the operational properties of the products is the thermal treatment of the forgings, which can be implemented in many variants, depending on the expected results. Unfortunately, a treatment of this type, realized separately after the forging process, is very time and energy-consuming; additionally, it significantly raises the production costs due to the increased energy consumption resulting from the necessity of repeated heating of the forgings for such thermal treatment. The article reviews the most frequently applied (separately, after the forging process) thermal treatments for die forgings together with the devices/lines assigned for them, as well as presents an alternative (thermoplastic) method of forging production with the use of the forging heat. The paper also presents a prototype semi-industrial controlled cooling line developed by the authors, which allows the development of the assumed heat treatment of forgings directly after forging with the use of forging heat, together with sample results of conducted tests.

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.

scholarly journals The use of a measuring arm with a laser scanner for analysis and support of regenerative surfacing processes of forging dies

2020 ◽  
Vol 92 (3) ◽  
pp. 23-32
Author(s):  
Marcin D. Kaszuba ◽  
Paweł Widomski ◽  
Tomasz Kiełczawa ◽  
Zbigniew Gronostajski
Keyword(s):  
Weld Metal ◽  
Laser Scanner ◽  
Regeneration Process ◽  
Forging Process ◽  
Machining Allowance ◽  
Energy Consuming ◽  
Pre Treatment ◽  
Forging Die ◽  
Time And Energy

The article presents the results of research conducted in order to develop the technology of regenerative surfacing of forging dies. The selected example shows how the use of a measuring arm with a laser scanner can be used to support the regeneration process. The tests were conducted in industrial conditions of a forging die. The analysis of the regeneration process was carried out at each of 4 stages: after wear in the forging process, after initial machining, after regenerative surfacing and after final machining. It has been shown that scanning can be used to develop programs for mechanical pre- treatment, to measure the volume of padding welds, to determine the amount of finishing allowance, to verify the effectiveness of the surfacing process and to control the quality of the die before the forging process. The obtained results confirmed the effectiveness of the regeneration carried out. In terms of performance, it has been shown that too much padding weld's material is a machining allowance. For this reason, the treatment is time and energy consuming and about 68% of the padding weld's material is waste or chips. The analysis showed the possibility of saving up to 45% of the weld metal material by using reasonable allowances of smaller thickness. These results indicate the need to modify the regeneration technology and the legitimacy of using robotic surfacing, which can provide greater precision and repeatability in the layingof padding weld’s beads. The next stage of research will be robotization of the analyzed forging die regeneration process using WAAM technology.

Investigation on Forging Process of S20S Connecting Rod and its Defects Analysis

2012 ◽  
Vol 538-541 ◽  
pp. 1646-1649
Author(s):  
Lu Zhou ◽  
Kai Kun Wang ◽  
Shi Lei Song ◽  
Lin Lu ◽  
Chong Wei Li
Keyword(s):  
Energy Spectrum ◽  
Energy Industry ◽  
Connecting Rod ◽  
Forming Process ◽  
Forging Process ◽  
Heavy Machinery ◽  
Large Size ◽  
Complex Process ◽  
Defects Analysis

In the heavy machinery and energy industry, forged connecting rods have been used more and more widely. Due to the complex process and large-size, it is a challenge to ensure the quality of large forgings. Different kinds of defects were produced during forming process. In this study, the forming process of S20S forged connecting rod was first analyzed. Then SEM and energy spectrum were conducted. The results showed that inclusions of sulfide and oxide were the main defects during forging of S20S connecting rod.

scholarly journals Quality Evaluation of Cold Embossed Hole Based on Profile Measurement Technique

2012 ◽  
Vol 626 ◽  
pp. 564-568
Author(s):  
A.B. Abdullah ◽  
S.M. Sapuan ◽  
Z. Samad ◽  
N.A. Aziz
Keyword(s):  
Aluminum Alloy ◽  
Measurement Technique ◽  
Quality Evaluation ◽  
Surface Measurement ◽  
Cold Forging ◽  
Design Parameters ◽  
Profile Measurement ◽  
Forging Process ◽  
Experimental Rig

The main objective of this study is to assess the quality of the cold forging hole by focusing the roundness of the hole. In this study, a cold forging process of blind hole of Aluminum Alloy AA6061 experimental rig was developed. In the experiment, two major design parameters i.e. the depth of embossing and diameter of the punch were studied and their influence to the roundness was measured based on the profile obtained from the surface measurement technique. The results will be validated using commercial roundtest machine.

A study of a new screw press forging process for producing aircraft drop forgings made of magnesium alloy AZ61A

2018 ◽  
Vol 90 (3) ◽  
pp. 559-565 ◽  
Author(s):  
Andrzej Gontarz ◽  
Krzysztof Drozdowski ◽  
Anna Dziubinska ◽  
Grzegorz Winiarski
Keyword(s):  
Magnesium Alloy ◽  
Production Efficiency ◽  
Ferrous Metal ◽  
Screw Press ◽  
Manufacturing Costs ◽  
Content Type ◽  
Fundamental Parameters ◽  
Forging Process ◽  
Die Forging

Purpose The aim of this study is to develop a die forging process for producing aircraft components made of magnesium alloy AZ61A using a screw press. Design/methodology/approach The proposed forging technique has been developed based on the results of a numerical and experimental research. The required forging temperature has been determined by upsetting cylindrical specimens on a screw press to examine both plasticity of the alloy and the quality of its microstructure. The next stage involved performing numerical simulations of the designed forging processes for producing forgings of a door handle and a bracket, both made of magnesium alloy AZ61A. The finite element method based on simulation programme, Deform 3D has been used for numerical modelling. The numerical results revealed that the forgings are free from material overheating and shape defects. In addition to this, the results have also helped determine the regions that are the most prone to cracking. The final stage of the research involved performing forging tests on a screw press under industrial conditions. The forgings of door handles and brackets were made, and then these were tested for their mechanical and structural properties. The results served as a basis for assessing both the viability of the designed technique and the quality of the produced parts. Findings The experimental results demonstrate that aircraft components made of magnesium alloy AZ61A can be produced by die forging on screw presses. The results have been used to determine the fundamental parameters of the process such as the optimum forging temperature, the method of tool heating, the way of cooling parts after the forging process, and the method of thermal treatment. The results of the mechanical and structural tests confirm that the products meet the required quality standards. Practical implications The developed forging technique for alloy AZ61A has been implemented by the forging plant ZOP Co. Ltd in Swidnik (Poland), which specializes in the manufacturing of aircraft components made of non-ferrous metal alloys. Originality/value Currently, the global tendency is to forge magnesium alloys (including alloy AZ61A) on free hydraulic presses using expensive die-heating systems. For this reason, the production efficiency of such forging processes is low, while the manufacturing costs are high. The proposed forging technique for alloy AZ61A is an innovative method for producing forgings using relatively fast and efficient machines (screw presses). The proposed forging method can be implemented by forging plants equipped with standard stocks of tools, which increases the range of potential manufacturers of magnesium alloy products. In addition, this technology is highly efficient and ensures reduced manufacturing costs.

scholarly journals Effect of Technical Quality of Thermomechanical Die Forging of AA2099 Alloy

2014 ◽  
Vol 59 (3) ◽  
pp. 997-1003
Author(s):  
A. Łukaszek-Sołek
Keyword(s):  
Numerical Modelling ◽  
Complex Shape ◽  
True Strain ◽  
Process Conditions ◽  
Technical Quality ◽  
Compression Tests ◽  
Forging Process ◽  
Die Forging ◽  
Microstructure Examination

Abstract The paper presents the results of investigations of a multicomponent third-generation aluminium alloy, classified as AA2099. The actual forging conditions were determined basing on the assessment of the quality of side surface of specimens subjected to compression in Gleeble 3800 simulator and on flow curves of the alloy, as well as numerical modelling of forging process performed with application of QForm 3D v.7 software. Compression tests were realized at temperatures 400-500 °C, with a strain rate of 0.001-100 s-1, up to a specified constant true strain value of 0.9. Microstructure examination in as-delivered state was performed with application of Leica DM 4000M optical microscope. The obtained results of isothermal deformation of specimens were correlated with the analysis of a characteristic layered pancake-type microstructure. The simulation of die forging of a complex-shape forging (high-current contact tip used in power engineering) at the temperature 500 °C, was performed. The shape of a forging makes it possible to fully analyse the influence of thermomechanical process conditions on technical quality of a product. The simulation of forging process showed full correctness of material flow, with no signs of instability. At the same time, the analysis of investigations allowed to prepare and realize the industrial forging trials for a forging of a very complex shape, in a single step, at the temperature 500 °C, with application of thermomechanical treatment. The forging attained high quality of shape and surface. Directional specimens were taken, in order to be subjected to microstructure examination and hardness testing. The data obtained from industrial tests, combined with the results of testing using Gleeble simulator as well as from numerical modelling, make up the guidelines for mechanical processing of AA2099 alloy at the temperatures 470-500 °C.

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