Experiment on parameters of new finish forging die structure of automobile crankshaft called resistance wall

In the present paper, the precision forging of an impeller was studied by means of numerical simulation and test forming. Based on the structure and dimension of the impeller, the combination structure was used in the forging die to obtain the extrusion deformation. The forming processes were simulated with DEFORM-3D for different billet dimensions and processing parameters. The parameters, which could ensure the forming quality of the impeller, were determined by the calculations and analysis. The die structure and the billet dimensions were determined according to the simulation results, and the forging die was designed and manufactured. The billet with semi-solid microstructure was produced by means of the direct heating-isothermal treatment. The forming was conduced in an YX-315F hydraulic press, and the precision forgings of the impeller were produced successfully. Both of the simulation and the forming test show that the impeller forging can be formed with the combination structure die and the extruding forming stale satisfactorily. The ideal parameters to produce the precision forgings of the impeller are: billet temperature at 625°C, die temperature at 450°C and punch speed at 20mm/s. Under these conditions, forgings of the impeller can be produced with plump blades, smooth outer surface, and good flow line. This can match the requirements of the precision forging of impellers.

Download Full-text

Structure Design and Research of Heat Pipe Cooled Hot Forging Die

Materials Science Forum ◽

10.4028/www.scientific.net/msf.770.414 ◽

2013 ◽

Vol 770 ◽

pp. 414-418

Author(s):

Wei Cheng ◽

Ping Liang

Keyword(s):

Temperature Field ◽

Heat Pipe ◽

Thermal Load ◽

Hot Forging ◽

Structure Design ◽

Computational Method ◽

Structure Model ◽

Hot Forging Die ◽

Die Structure ◽

Forging Die

This paper describes the structure of heat pipe cooled hot forging die. A computational method was used to predict the temperature field of the die structure model. The research results show that the heat pipe can be effective cooled hot forging die, the temperature values of around heat pipe have a declining greater, thus significantly reducing the thermal load of the hot forging die, to further extend the life of the die.

Download Full-text

Optimization Design of Forging Die for Supporting Bar Based on DEFORM-3D

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.602-604.1869 ◽

2012 ◽

Vol 602-604 ◽

pp. 1869-1873

Author(s):

Lei Fu ◽

Li Lin

Keyword(s):

Contact Stress ◽

Optimization Design ◽

Working Life ◽

Work Piece ◽

Die Structure ◽

Die Stress ◽

Simulation Results ◽

3D Solid ◽

Forging Die ◽

Deform 3D

On the basis of analyzing the process of supporting bar forging conform, the 3D solid geometries modeling of billet and die were constructed by SOLIDWORKS software, the distributions of die stress and contact stress on the process of supporting bar forging conform were analyzed by using DEFORM-3D program. The working life of the die punch was assessed. The die structure was optimized based on the simulation results, and the forging defect of the improved work piece could be well controlled and the die working life was improved to about 10%.

Download Full-text

Research of Die Cavity Warm Extrusion on 3Cr2W8V Steel One-Off Forming Technology

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.418-420.1270 ◽

2011 ◽

Vol 418-420 ◽

pp. 1270-1273

Author(s):

Wei Du ◽

Guo Sen Yuan ◽

Cheng Bin Li

Keyword(s):

Service Life ◽

Structure Parameters ◽

Extrusion Die ◽

Forming Technology ◽

Forming Parameters ◽

Die Forging ◽

Die Structure ◽

Extrusion Forming ◽

Forging Die ◽

Warm Extrusion

The problems of 3Cr2W8V steel concave die forging production must be solved, such as too many procedures, high cost and mold crack. Through the use of a warm extrusion forming method it could make one-off forming die cavity come true, more practical warm extrusion forming parameters and extrusion die structure parameters were obtained. A suitable lubricant was selected out so that the processed forging die organization was improved and forging streamline distribution was more rational. The service life of forging die increased, and warm extrusion forming technology was applied in the mold production.

Download Full-text

An Investigation of Hot Forging Die Wear Based on FEA

Materials Science Forum ◽

10.4028/www.scientific.net/msf.861.207 ◽

2016 ◽

Vol 861 ◽

pp. 207-215 ◽

Cited By ~ 2

Author(s):

Zhao Hui Wang ◽

Cheng Hao Luan ◽

Bao Ju Li ◽

Jia Tai Yang

Keyword(s):

Hot Forging ◽

Finite Element Method Simulation ◽

Wear Depth ◽

Wear Model ◽

Die Wear ◽

Hot Forging Die ◽

Steady State Temperature ◽

Die Structure ◽

Preheating Temperature ◽

Forging Die

Taking the forging die of an automobile differential shell as example, the influence of some die forging process parameters and die structure parameters on the die wear was investigated. Based on a modified Archard wear model and the application of finite element method simulation, the die wear depth was calculated under a steady state temperature field. Within the scope of the experimental data, the research shows that: with the increase of billet preheating temperature, the wear is reduced gradually. Improving die preheating temperature, the wear increases gradually. When the forming speed is 300mm/s~400mm/s, the wear value decreases first and then increases.When the forming speed is over than 400mm/s, the change of wear value is not obvious. Increasing flash thickness and round radius, the wear value reduces gradually.

Download Full-text

Numerical Analysis on Precision Forging of 7A09 Aluminum Impeller

Materials Science Forum ◽

10.4028/www.scientific.net/msf.628-629.535 ◽

2009 ◽

Vol 628-629 ◽

pp. 535-540 ◽

Cited By ~ 1

Author(s):

Wei Wei Wang ◽

Jian Li Song ◽

Fei Han ◽

Shou Jing Luo

Keyword(s):

Flow Line ◽

Metal Flow ◽

Forming Process ◽

Precision Forging ◽

Die Structure ◽

Forming Characteristics ◽

Forging Die ◽

Deform 3D ◽

Forging Load ◽

Good Flow

Numerical simulation and test forming of the isothermal precision forging of an impeller was carried out. The forming processes were simulated with DEFORM-3D to obtain the forming characteristics and metal flow pattern. It indicated that the impeller can be forged by the method of isothermal-forging, and the deforming process can be divided into 3 stages. The forming of blades was depended on the extrusion of materials. During the forming, uneven deformation was existed in the billet, especially in the field of the blade root. The forging load was increased rapidly during the later stage of the forming process, and the maximum forging load was about 2961kN. According to the simulations, the die structure and the billet dimension were determined, the forging die was designed and manufactured, and the precision forgings of the impeller were produced successfully. Both of the simulation and the test forming indicated that the impeller forging could be performed with the assembled structure die and the isothermal extruding forming style satisfactorily. The ideal parameters to produce the precision forgings of the impeller are: a forging temperature of 450°C and a punch speed of 1mm/s. Under these conditions, the forgings of the impeller can be produced with full blades, smooth outer surface and good flow line, which can meet the requirements of the precision forging of impellers.

Download Full-text

Numerical Simulation and Process Optimization of the Die Forging for the Center Wedge of the Railway Freight Car Buffers

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.228-229.412 ◽

2011 ◽

Vol 228-229 ◽

pp. 412-415 ◽

Cited By ~ 1

Author(s):

Yu Zhang ◽

Zhi Guo An ◽

Lu Li

Keyword(s):

Die Design ◽

Forming Process ◽

Forging Process ◽

Railway Freight ◽

Utilization Coefficient ◽

Die Structure ◽

Freight Car ◽

Working Procedure ◽

Forging Die ◽

Railway Freight Car

Aiming at the center wedge of the railway freight car buffers, the forging process was analyzed and the die design was optimized. The direct finish-forging process after pre-forming process was contrasted with the finish-forging after pre-forging based on pre-forming process, and the influence of different billet sizes and die structures on the forming were analyzed and compared. To validate the different process scheme and die structure, the numerical simulations were done using FEM software deform3D. The results show that the filling capacity of billet to die cavity increases greatly by using direct finish-forging process and finish-forging die with the resistance wall and the utilization coefficient of materials is improved. This can reduce working procedure and improve the productivity.

Download Full-text

A Multi-Level Low Cycle Fatigue Damage Model for Forging Die Material

Materials Science Forum ◽

10.4028/www.scientific.net/msf.514-516.804 ◽

2006 ◽

Vol 514-516 ◽

pp. 804-809

Author(s):

S. Gao ◽

Ewald Werner

Keyword(s):

Fatigue Life ◽

Fatigue Damage ◽

Low Cycle Fatigue ◽

Damage Model ◽

Fatigue Loading ◽

Cycle Fatigue ◽

Die Material ◽

Multi Level ◽

Loading Sequence ◽

Forging Die

The forging die material, a high strength steel designated W513 is considered in this paper. A fatigue damage model, based on thermodynamics and continuum damage mechanics, is constructed in which both the previous damage and the loading sequence are considered. The unknown material parameters in the model are identified from low cycle fatigue tests. Damage evolution under multi-level fatigue loading is investigated. The results show that the fatigue life is closely related to the loading sequence. The fatigue life of the materials with low fatigue loading first followed by high fatigue loading is longer than that for the reversed loading sequence.

Download Full-text