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.

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.

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.

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.

scholarly journals A comparative analysis of hot and cold flashless forging of a stepped shaft using vertically-parted dies

2021 ◽  
Author(s):  
Tomasz Bulzak ◽  
Janusz Tomczak ◽  
Zbigniew Pater
Keyword(s):  
Comparative Analysis ◽  
Metal Forming ◽  
Effective Strain ◽  
Hot Forging ◽  
Cold Forging ◽  
Geometrical Parameters ◽  
Forging Process ◽  
Stepped Shaft ◽  
One Step ◽  
Hot Forging Process

AbstractFlashless forging is classified as a precise metal forming technology. The main advantages of this technology are the reduction of the flash allowance and the shortening of the manufacturing time by eliminating the flash trimming operation. The article presents the process of one-step forging of a stepped shaft made of aluminum with the use of split dies. The process was carried out in cold and hot metal-forming conditions. The forging process was analyzed numerically using the Simufact Forming 15.0 software. The geometrical parameters of the obtained product were analyzed, and the distribution of effective strain, temperature, and the standardized cracking criterion was determined. The process force parameters were also determined. Numerical tests were verified in real conditions with the use of a specially designed device for forging in vertical split dies. Comparison of hot and cold forging in vertical split dies is presented. The comparative analysis results have demonstrated that the hot forging process has more advantages than the cold forging process. The hot forging process ensures higher accuracy of forged parts.

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.

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
Sign in / Sign up

Export Citation Format

Share Document