Preform design in axial hot closed die forging by isothermal surface method. Part 1. Overview of preform design methods. Theoretical aspects and algorithm of preform shape design

2021 ◽  
pp. 214-220
Author(s):  
A.V. Vlasov ◽  
D.V. Krivenko ◽  
S.A. Stebunov ◽  
N.V. Biba ◽  
A.M. Dyuzhev
Keyword(s):  
Simulation Software ◽  
Preform Design ◽  
Mathematical Basis ◽  
Design Algorithm ◽  
Forming Simulation ◽  
Die Geometry ◽  
Die Forging ◽  
Closed Die Forging ◽  
Trial And Error Method ◽  
Preform Shape

Methods of preform design in hot-die forging are analyzed. It is noted that despite numerous works in this fi eld, preform design is still often based on the trial-and-error method. The isothermal surfaces method for preform design is proposed and its mathematical basis is considered. The procedure for determining of the preform shape is given. The design algorithm uses the QForm metal forming simulation software to build isothermal surfaces and check in the quality of the designed die geometry by finite element modeling, as well as specially developed version of the QFormDirect CAD based on SpaceClaim™.

Preform design in axial hot closed die forging by isothermal surface method. Part 3. Preform design of industrial cases

2021 ◽  
pp. 305-313
Author(s):  
A.V. Vlasov ◽  
D.V. Krivenko ◽  
S.A. Stebunov ◽  
N.V. Biba ◽  
A.M. Dyuzhev
Keyword(s):  
Metal Forming ◽  
Simulation Software ◽  
Preform Design ◽  
Design Algorithm ◽  
Forming Simulation ◽  
Die Geometry ◽  
Surface Method ◽  
Closed Die Forging ◽  
Preform Shape

The isothermal surfaces method for preform design is proposed. The procedure for determining of the preform shape is given. The features in using of the method for forgings with various shapes are considered. The method is illustrated by industrial examples. The design algorithm uses the QForm metal forming simulation software to build isothermal surfaces and check the quality of the designed die geometry by finite element modeling, as well as specially developed version of the QFormDirect CAD based on SpaceClaimтм.

Preform design in axial hot closed die forging by isothermal surface method. Part 2. Application of isothermal surfaces method for complex shape forgings

2021 ◽  
pp. 268-272
Author(s):  
A.V. Vlasov ◽  
D.V. Krivenko ◽  
S.A. Stebunov ◽  
N.V. Biba ◽  
A.M. Dyuzhev
Keyword(s):  
Complex Shape ◽  
Simulation Software ◽  
Preform Design ◽  
Design Algorithm ◽  
Forming Simulation ◽  
Die Geometry ◽  
Surface Method ◽  
Closed Die Forging ◽  
Preform Shape

The isothermal surfaces method for preform design is proposed. The procedure for determining of the preform shape is given. The features in using of the method for forgings with various shapes are considered. The method is illustrated by industrial examples. The design algorithm uses the QForm metal forming simulation software to build isothermal surfaces and check the quality of the designed die geometry by finite element modeling, as well as specially developed version of the QFormDirect CAD based on SpaceClaimтм.

Numerical Simulation Analysis on Cold Closed-Die Forging of Differential Satellite Gear in Car

2008 ◽  
Vol 575-578 ◽  
pp. 517-524 ◽  
Author(s):  
Yao Zong Zhang ◽  
Jian Bo Huang ◽  
Xue Lin ◽  
Quan Shui Fang
Keyword(s):  
Numerical Simulation ◽  
Simulation Analysis ◽  
Simulation Software ◽  
Bevel Gear ◽  
Cold Forging ◽  
Forging Process ◽  
Die Forging ◽  
Closed Die Forging ◽  
Forming Defects ◽  
Deform 3D

The cold closed-die forging process of the gear is a kind of new technique of the precise forming of gear in recent years. In this paper, the cold closed-die forging process of differential satellite gear in car was analyzed through numerical simulation method. Forming mold was designed with Pro/E Wildfire2.0 which included four components : upper punch, lower punch, tooth shape upper die and lower die for Normal Cone. The three-dimensional models of satellite bevel gear mould were built and imported into numerical simulation software DEFORM-3D. Because the gear has the uniform circumferential features, in order to save time and improve the accuracy, only one tooth was simulated, and the full simulation outcome of 10 teeth was mirrored from this one. Through the numerical simulation analysis of DEFORM-3D, the instantaneous deformation and stress filed were gained. Forming defects were forecasted and the cold closed-die forging rule for satellite gear used in car was obtained which can provide effective references for no-flash cold forging process of planet bevel gear and the mold design.

scholarly journals Closed Die Forging Preform Shape Design Using Isothermal Surfaces Method

2020 ◽  
Vol 47 ◽  
pp. 268-273
Author(s):  
Nikolay Biba ◽  
Andrey Vlasov ◽  
Dmitry Krivenko ◽  
Alexey Duzhev ◽  
Sergey Stebunov
Keyword(s):  
Shape Design ◽  
Die Forging ◽  
Closed Die Forging ◽  
Preform Shape

The Rationalization of Production of Ring-Shaped Drop Forgings Using Computer Simulation of Closed-Die Forging Process

2015 ◽  
Vol 660 ◽  
pp. 335-339
Author(s):  
Mária Kapustová
Keyword(s):  
Energy Savings ◽  
Simulation Software ◽  
Advanced Technology ◽  
Material Loss ◽  
Bulk Forming ◽  
Die Forging ◽  
Closed Die Forging ◽  
Alloy Type ◽  
Drop Forging ◽  
Important Position

The rationalization of ring-shaped drop forgings production may be considered from different points of view. Important aspects of evaluation and selection of optimal production alternative are material and energy savings and issue of forging tool life. This contribution describes advanced technology of closed die forging without flash, which represents an effective method of manufacture of ring-shaped drop forging from steel alloy type 16MnCr5. This proposed method offers a cheaper possibility of production of mentioned forging piece resulting from saving of batch material. At present drop forgings with this shape are produced by an uneffective method, i.e. die forging with flash, which brings a considerable material loss. Simulation software determined for simulation of bulk forming processes have an important position at development of new advanced technologies of drop forgings production. A simulation program MSC.SuperForge described in this contribution was used in order to verify correct plastic flow of material in closed die cavity.

Preform Design in Metal Forming

1989 ◽  
Author(s):  
Shiro Kobayashi ◽  
Soo-Ik Oh ◽  
Taylan Altan
Keyword(s):  
Metal Forming ◽  
Simulation Technique ◽  
Production Costs ◽  
Process Conditions ◽  
Preform Design ◽  
Forward Simulation ◽  
Forming Process ◽  
Closed Die Forging ◽  
Preform Shape

Preform design in metal forming refers to the design of an initial shape of the workpiece that, when it has undergone an associated forming process, forms the required product shape with desired property successfully without formation of defects and without excessive waste of materials. A carefully selected preform can contribute significantly to the reduction of the production costs. Preform design problems are encountered in various metal-forming processes, such as closed-die forging, shell nosing, rolling, and sheet-metal forming. Design of an optimal preform shape requires simultaneous determination of optimal process conditions. However, we are here concerned with the determination of the best preform shape under a given set of process conditions. In this chapter, a new method of “backward tracing” is introduced as an alternative approach to the solution of preform design, and the applications of this method to some specific processes are discussed. Similarly to the forward simulation technique, the backward tracing method uses the finite-element method. The forward simulation technique has been discussed in the previous chapters. Backward tracing refers to the prediction of the part configuration at any stage in a deformation process, when the final part geometry and process conditions are given. The concept is illustrated in Fig. 15.1. At time t = t0, the geometrical configuration x0 of a deforming body is represented by a point Q. The point Q is arrived at from the point P, whose configuration is given as x0–1 at t = t0–1, through the displacement field during a time-step Δt, namely, x0 = x0–1 + u0–1 Δt, where u0–1 is the velocity field at t = t0–1. Therefore, the problem is to determine u0–1, based on the information (x0) at point Q. The solution scheme is as follows: taking a loading solution u0 (forward) at Q, a first estimate of P can be made according to P(1) = x0 – u0 Δt.

Closed-Die Forging of Gear-Like Elements

1998 ◽  
Vol 120 (1) ◽  
pp. 34-41 ◽  
Author(s):  
A. El-Domiaty ◽  
M. Shabara ◽  
M. Al-Ansary
Keyword(s):  
Upper Bound ◽  
Pure Aluminum ◽  
Experimental Results ◽  
Frictional Stress ◽  
Die Geometry ◽  
Die Forging ◽  
Closed Die Forging ◽  
Theoretical Predictions ◽  
Upper Bound Technique ◽  
Forging Die

Closed die forging of spur gears is investigated using the slab method and the upper bound technique. The tooth regions are approximated by prismatic rectangular sections. The velocity field comprising three unit deformation regions is used. A constant frictional stress between workpiece and forging die is assumed. The average punch pressure normalized by the flow stress of the gear material is determined theoretically and compared with experimental results. The experimental work is carried out on a commercial pure aluminum (Al 1100) at room temperature. The forging process is carried out using one die geometry without using any additional blocker (preform) dies. The theoretical predictions of forging pressures using slab and upper bound methods agree fairly well with the experimental results.

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