Direct Heating Billet within Die during Hot Forging Process

2013 ◽  
Vol 479-480 ◽  
pp. 25-29 ◽  
Author(s):  
Fang Sung Cheng ◽  
Yu Shun Cheng
Keyword(s):  
Hot Forging ◽  
High Strength ◽  
Heating System ◽  
Heating Time ◽  
Resistance Heating ◽  
Heating Efficiency ◽  
Forging Process ◽  
Direct Heating ◽  
Forging Die ◽  
Hot Forging Process

This paper reports a simple and effective method to increase heating efficiency and decrease heating time that renders direct heating billet within die using resistance heating system during hot forging process. The apparatus employs resistance equipment set into the forging die, and the billet was directly resistance heating by the forging die. Base on the approach, the die as a forming condition on direct heating and forging was also researched. The result of experiments shows that the billet could be heated quickly to 1000°C in about 5 seconds and the high strength material (AISI4140) was successfully formed to the shape of bolt head. With this mechanism, the rapidly heating and isothermal deformation during the hot forging process can be achieved.

One-Step Gradual Forging Process by Using Direct Heating Billet within Die

2015 ◽  
Vol 764-765 ◽  
pp. 122-126
Author(s):  
Fang Sung Cheng ◽  
Yu Shun Cheng
Keyword(s):  
Hot Forging ◽  
High Strength ◽  
Experimental Result ◽  
Forging Process ◽  
Direct Heating ◽  
Gradual Deformation ◽  
One Step ◽  
Strength Material ◽  
Forging Die ◽  
Hot Forging Process

Direct heating billet within a die by using resistance heating method was developed to form the high strength material in one-step gradual forging process. During the forging process, the pressing speed of the upper die is controlled with the pace of the heating billet. In the proposed method, the forging die can be used as both the forming and heating of the billet. Based on this innovative forming method, experimental result shows that the billet could be heated quickly to 1000oC in about 5 seconds and the high strength material was successfully formed to the shape of bolt head in one-step gradual forging process. With the proposed mechanism, the rapidly heating and gradual deformation during the hot forging process can be successfully carried out.

Flash Design for Automatic Transfer System of Bearing Hub in Hot Forging Process

2006 ◽  
Vol 116-117 ◽  
pp. 120-123
Author(s):  
Sang Kon Lee ◽  
Hyun Sang Byun ◽  
Byung Min Kim ◽  
Dae Cheol Ko ◽  
C.G. Kang
Keyword(s):  
Numerical Analysis ◽  
Metal Flow ◽  
Hot Forging ◽  
Experimental Results ◽  
Transfer System ◽  
Forging Process ◽  
Hot Forging Die ◽  
Forging Die ◽  
Hot Forging Process ◽  
Forging Load

The aim of this study is to design flash geometry of bearing hub to apply the automatic transfer system in hot forging process. The flash geometry is very important in hot forging process because the flash geometry effects on the metal flow, material losses, forging load, die pressure and so on. In this study, the problem of designing the flash geometry is studied with flash thickness and width considering the maximum die pressure to apply an automatic transfer system in hot forging process for bearing hub. The numerical analysis was conducted by means of the commercial S/W DEFORM. On the basis of numerical analysis the flash geometry of hot forging die was redesigned, and experiment was conducted. From the experimental results, it was possible to produce bearing hub with an automatic transfer system without any deterioration of die lifetime.

scholarly journals Parametric optimization of hot forging process: a six sigma based approach

2021 ◽  
Vol 309 ◽  
pp. 01159
Author(s):  
Kumar Satyam ◽  
Divya Prakash Srivastava ◽  
Saurabh Kumar ◽  
Rajkumar Ohdar
Keyword(s):  
Quality Improvement ◽  
Process Parameters ◽  
Six Sigma ◽  
Hot Forging ◽  
Critical Parameters ◽  
Modern World ◽  
Connecting Rod ◽  
Forging Process ◽  
Forging Die ◽  
Hot Forging Process

One of the major concerns for industries in the modern world is to focus efforts on producing high quality products with minimal costs. Various quality improvement philosophies have emerged in recent times, Six Sigma being one of the most practical and efficient techniques for quality improvement of processes. In this work, Six Sigma based DMAIC (Define, Measure, Analyze, Improve, Control) approach is used to enhance productivity and quality performance, and to make the hot forging process robust to quality variations. Finite element method has been employed for the simulation of hot forging of the connecting rod. The influence of design and process parameters is investigated for the response ‘forging die load’. Analysis of various critical parameters and the interaction among them has been carried out with the help of Taguchi’s method of experimental design. To further optimize the response and make the analysis more precise and robust, response surface methodology has been incorporated. Parameters have been optimized, leading to the accomplishment of a minimized forging die load which is verified using a confirmation experiment. Confirmatory results reveal the potential of the DMAIC approach of Six Sigma in optimizing the process parameters successfully and thereby present significant applicability in the industry.

Using Soft Material as Die during Hot Forging

2013 ◽  
Vol 479-480 ◽  
pp. 30-34
Author(s):  
Fang Sung Cheng ◽  
Yi Sheng Chen
Keyword(s):  
Heat Transfer ◽  
Flow Stress ◽  
Hot Forging ◽  
Spur Gear ◽  
Soft Material ◽  
Resistance Heating ◽  
High Alloy ◽  
Forging Process ◽  
Hot Forging Process

This study introduces a new forming concept for hot forging by using soft die. The soft die (AISI1050) was employed not only to heating the billet, but also to forming the billet. In this proposed method, the soft die can be used as the electrode to raise the temperature of billet directly by resistance heating. The temperature of the billet is higher; the flow stress of the billet is become lower. Then the billet is easier to press into the cavity of the soft die. In addition, the soft die itself could not be heated by the electrifying and the temperature raise of soft die was occurred by the heat transfer from the heated billet. Therefore, the soft die can be carried out on hot forging process, and to achieve the purpose of forming. The result of experiments shows that the billet could be heated quickly to 1000°C in about 5 seconds, and a spur gear was successfully formed. With the proposed method, it was simple enough to hot forging high-alloy metals with poor workability.

scholarly journals The use of electromagnetic field in designing the high quality Al alloys for hot forging process

2014 ◽  
Vol 20 (4) ◽  
pp. 247-254
Author(s):  
Zvonko Gulišija ◽  
Aleksandra Patarić ◽  
Marija Mihailović
Keyword(s):  
Electromagnetic Field ◽  
Hot Forging ◽  
High Strength ◽  
Casting Process ◽  
Al Alloy ◽  
Forging Process ◽  
Fine Grained ◽  
Complex Dimensions ◽  
Strength Alloy ◽  
Hot Forging Process

This work presents a way to obtain the better quality of EN AW 7075 aluminum high-strength alloy by application of electromagnetic field (EMF) during the casting process. In this way, the uniform fine-grained microstructure, and hence the better mechanical properties of the alloy can be achieved. The microstructure and mechanical characterization for samples obtained with and without EMF were performed. The application of numerical simulation for hot forging process, using appropriate software, is efficient and highly useful tool for problem prediction in industrial production, reducing the time and costs in the process of development of new products. The input data of high strength Al-alloy EN AW-7075 is used for simulation because it enables the development of parts with complex dimensions and shape. 

Effect of Preform Height on Die Wear in Hot Forging Process of Idle Gear by Finite Element Modeling

2017 ◽  
Vol 728 ◽  
pp. 36-41 ◽  
Author(s):  
Panuwat Soranansri ◽  
Mahathep Sukpat ◽  
Taweesak Pornsawangkul ◽  
Pinai Mungsantisuk ◽  
Kumpanat Sirivedin
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Failure Modes ◽  
Hot Forging ◽  
Wear Depth ◽  
Forging Process ◽  
Element Modeling ◽  
Die Wear ◽  
Forging Die ◽  
Hot Forging Process

In hot forging process, the common failure modes of forging die are wear, fatigue fracture and plastic deformation. Normally die wear is occurred the most frequently and it influents directly to shape, dimension and surface quality of product. For this research, the hot forging process of idle gear was studied to focus on die wear. This product is forged in three steps. There are preform step, rougher step and finisher step. Height of preform shape in preform step was a parameter to study effect on die wear. Archard’s wear model in finite element modeling was used to predict die wear. The finite element modeling was verified by real hot forging process for reliable model and then it was used to determine the optimum preform height to reduce die wear. Finally the result showed that the maximum wear depth on the forging die was reduced 41.2% from original industry process.

Experimental Study of Hot Forming Process by Direct Resistance Heating

2011 ◽  
Vol 704-705 ◽  
pp. 252-260 ◽  
Author(s):  
Zheng Xing Men ◽  
Jie Zhou ◽  
Zhi Min Xu
Keyword(s):  
Experimental Study ◽  
Plastic Deformation ◽  
Hot Forging ◽  
Heating Time ◽  
Resistance Heating ◽  
Forming Process ◽  
Heating Efficiency ◽  
Cylindrical Billet ◽  
Forming Temperature ◽  
Forming Condition

In order to increase heating efficiency and decrease heating time, a new hot-forging method by means of direct resistance heating was investigated in this paper. Based on the approach, the hot upsetting experiments with cylindrical billet of 42CrMo4 were performed. Moreover, the influence of the multi-layer aluminium foils inserted between the billet and the die as a forming condition on heating and forming was researched. The results of the experiments show that prior to forming the billet could be heated quickly to forming temperature in about 10 seconds. During the upsetting process the billet cooling rate was effectively decreased and the forming time was extended in relation to the resistance heating. The insertion of multi-layer aluminium foils not only improved the efficiency of the heating, but also avoided the plastic deformation of the die and the occurrence of cracks on the billet’s surface. Keywords: Resistance heating, Hot forging, upsetting, Aluminium foils Introduction

Study of the applicability of 22MnB5 sheet metal as protective masks to improve tool life in hot forging process

2020 ◽  
Vol 107 (1-2) ◽  
pp. 39-47
Author(s):  
Luana De Lucca de Costa ◽  
Alberto Moreira Guerreiro Brito ◽  
André Rosiak ◽  
Lirio Schaeffer
Keyword(s):  
Sheet Metal ◽  
Tool Life ◽  
Hot Forging ◽  
Forging Process ◽  
Hot Forging Process
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