Claw-Pole Closed Forging Process

2014 ◽  
Vol 912-914 ◽  
pp. 605-608 ◽  
Author(s):  
Xuan Rong Xin ◽  
Ding Xu ◽  
Cheng Song He ◽  
Xin Cheng Liu
Keyword(s):  
Mass Production ◽  
New Technology ◽  
Extrusion Process ◽  
Forming Force ◽  
Short Life ◽  
Forging Process ◽  
New Process ◽  
Corner Filling ◽  
Hot Die Forging ◽  
Deform 3D

Aimed at the present domestic problems in the forging process of claw pole, such as insufficient corner filling, excessive forming force and short life of dies. On the basis of the analyzing in the claw pole, a new process named the closed hot die forging, direct extrusion process of claw pole is constituted. The numerical simulation using DEFORM-3D and the special mould are used in the forging experiment in order to check the new process. The results show that, new technology has greatly reduced the forming force, thereby reducing the production processes and improving the life of dies for mass production.

Large-Size Wheel Rotary Forging Process Research

2013 ◽  
Vol 456 ◽  
pp. 282-285 ◽  
Author(s):  
Jian Li ◽  
Hui Xue Sun ◽  
Li Mei Wang ◽  
Mu Hua Tao
Keyword(s):  
Energy Consumption ◽  
New Technology ◽  
High Energy ◽  
Production Costs ◽  
Forming Force ◽  
Forging Process ◽  
Rotary Forging ◽  
Large Size ◽  
Process Route ◽  
Small Influence

For forging process of the large size alloy wheels have several disadvantages, such as using large tonnage presses, high energy consumption, etc.So rotary-forging process route is developed. Forgings forming require 5000-6000T presses by the traditional process, but only require 350T rotary forging presses by new technology. This new process reduces the production costs and energy consumption and extends the life of die. Investigate the effect of several key factors on the forming force. The results show that forming force decreases with the decrease of press amount per turn, and reduce with the die and bars temperature increases. Forging wheel window has small influence on the forming force, but can decrease the forgings cutting weight, improve material utilization. This study plays a guiding role for equipment R & D and determination of the production processes parameters.

scholarly journals Hot Deformation Behavior and Dynamic Recrystallization of Ultra High Strength Steel

Metals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 1239
Author(s):  
Liping Zhong ◽  
Bo Wang ◽  
Chundong Hu ◽  
Jieyu Zhang ◽  
Yu Yao
Keyword(s):  
Martensitic Steel ◽  
High Strength ◽  
Experimental Results ◽  
Hot Deformation Behavior ◽  
Thermal Compression ◽  
Forging Process ◽  
Finite Element Software ◽  
Ultra High Strength Steel ◽  
Recrystallized Grain Size ◽  
Deform 3D

In this paper, in order to improve the microstructure uniformity of an ultra-high strength martensitic steel with a strength greater than 2500 MPa developed by multi-directional forging in the laboratory, a single-pass hot compression experiment with the strain rate of 0.01 to 1 s−1 and a temperature of 800 to 1150 °C was conducted. Based on the experimental data, the material parameters were determined, the constitutive model considering the influence of work hardening, the recrystallization softening on the dislocation density, and the recrystallized grain size model were established. After introducing the model into the finite element software DEFORM-3D, the thermal compression experiment was simulated, and the results were consistent with the experimental results. The rule for obtaining forging stock with a uniform and refinement microstructure was acquired by comparing the simulation and the experimental results, which are helpful to formulate an appropriate forging process.

Die Forging Process Simulation of a Connecting Rod

2011 ◽  
Vol 704-705 ◽  
pp. 302-307
Author(s):  
Lei Xu ◽  
Guang Ze Dai ◽  
Xing Ming Huang ◽  
Jing Han ◽  
Jun Wen Zhao
Keyword(s):  
Reduction Rate ◽  
Temperature Fields ◽  
Stress Fields ◽  
Connecting Rod ◽  
Preheat Temperature ◽  
Forging Process ◽  
Optimum Parameters ◽  
Die Forging ◽  
High Level ◽  
Deform 3D

Numerical simulation of connecting rod die forging processing was performed by finite element method (FEM) software Deform 3D. The changes of the temperature fields, stress fields of the billet and dies, and upper setting force-stroke curve during the die forging were obtained. The simulation results show that (1) the increase of the fillet radius of dies could effectively reduce the stress concentration so that to prevent the die crack arising at high level stress; (2) the optimum parameters of die forging process are 430°C for forging temperature, 200°C for preheat temperature of dies and 80mm/s for reduction rate by comparing both fields of the stress and temperature during different forging process..

Influence of Heating Models on Necking Deformation during Tube Extrusion Process

2011 ◽  
Vol 189-193 ◽  
pp. 1778-1781 ◽  
Author(s):  
Gui Hua Liu ◽  
Yong Qiang Guo ◽  
Zhi Jiang
Keyword(s):  
Temperature Gradient ◽  
Material Flow ◽  
Extrusion Process ◽  
Work Piece ◽  
Tube Extrusion ◽  
Deformation Parameters ◽  
Flow Features ◽  
Extrusion Forming ◽  
3D Software ◽  
Deform 3D

By using Deform-3D software, the necking extrusion forming processes of integer trailer axle with two different heating means which are Uniform Heating (UH) method and Partly Heating (PH) method with temperature gradient are simulated. The influence of deformation parameters such as friction factor, necking coefficient, different temperature distribution of work-piece on the material flow features, stress and strain field, loading force and deformation process are analyzed in detail. According to the numerical simulation results, using PH method with temperature gradient can improve necking deformation during tube extrusion process.

Simulation on Flexible Thixo-Extrusion of Variable Cross-Section Part Based on DEFORM-3D Software

2014 ◽  
Vol 217-218 ◽  
pp. 201-207
Author(s):  
Chun Fang Wang ◽  
Kai Kun Wang ◽  
Zhe Luo
Keyword(s):  
Aluminum Alloy ◽  
Control Method ◽  
Complex Geometry ◽  
Variable Cross Section ◽  
Extrusion Process ◽  
Simulation Software ◽  
Variable Cross ◽  
Stress Strain ◽  
Different Temperatures ◽  
Deform 3D

Flexible thixo-extrusion, as an innovative near-net-shape forming method, has huge advantages in processing the components with complex geometry. However, it should keep in mind that conventional liquid casting still represents the dominant mean of aluminum alloys production. One of the obstacles the thixo-extrusion has to overcome is lack of proof that can live up to the claim that thixo-extruded components have better mechanical properties. The main aim of this paper is to simulate the flexible thixo-extrusion process of aluminum alloy A356 and investigate the control method of materials flow front. An isothermal compression test of aluminum alloy A356 is first conducted to obtain the true stress-strain curves at different temperatures and strain rates. A constitutive equation describing the relationship of stress, strain, strain rate and temperature is fitted by Origin and then imported to the DEFORM-3D simulation software. The results show that the quality of final component is enormously influenced by the radius of the arcs and the flexible thixo-extruded components has less defects compared with the conventional extruded ones.

Influence of Roller on Tooth Height of Internal Spline Formed by Spin-Forming

2012 ◽  
Vol 522 ◽  
pp. 268-271
Author(s):  
Ling Yan Sun ◽  
Qin Xiang Xia ◽  
Xiu Quan Cheng ◽  
Bang Yan Ye
Keyword(s):  
New Technology ◽  
Internal Surface ◽  
Height Distribution ◽  
Forming Force ◽  
Nose Radius ◽  
Forming Process ◽  
Element Simulation ◽  
Gear Manufacturing ◽  
Spinning Force

Spin-forming of part with internal tooth is a new technology of the near-net forming in gear manufacturing field. And the main purpose of the parts spin-forming is to shape teeth on the internal surface of blank. In order to improve the forming quality of internal tooth, the effect of roller on tooth height of spline was investigated by processing experiments and finite element simulation. The result indicates that, for full-radius roller, a large nose radius has also witnessed a discernible growth in spinning force and tooth height; considering the uniformity of tooth height distribution of spun part and decrease in forming force, the bio-conical roller is more suitable for this forming process

Analysis of a new process of forging a 2017A aluminium alloy connecting rod

2021 ◽  
pp. 1-32
Author(s):  
Grzegorz Winiarski ◽  
Anna Dziubinska
Keyword(s):  
Aluminium Alloy ◽  
The Finite Element Method ◽  
Connecting Rod ◽  
Sand Cast ◽  
Input Material ◽  
Lower Strain ◽  
New Process ◽  
Billet Material ◽  
Hammer Forging ◽  
Deform 3D

Abstract The paper presents the results of a theoretical analysis of a new process of hammer forging of a connecting rod and the technology currently used. In the industry at present connecting rods are forged from extruded rods. The new forging technology assumes the use of a billet in the form of a cast preform. For the calculations, it has been assumed that the billet material will be a Ø30 x 148 mm rod and a cast preform. Two variants of preforms have been modelled, from which products of the assumed geometry with different degree of strain are obtained. Calculations were made using the finite element method in the Deform 3D program. The input material was 2017A aluminium alloy in the form of rods and sand cast preforms. On the basis of the conducted research it was found that the use of cast preforms reduces material waste by about 80% in relation to the technology of forging from the bar, and reduces the energy consumption of the process by about 75%. Both geometrical variants of the forging preforms ensure obtaining a forging with the assumed shape and dimensions, although forging from the forging preform with a smaller degree of strain seems to be a safer variant in terms of the possibility of cracking of the material. This is supported by the lower strain and Cockcroft-Latham integral values.

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.

An Innovative Compression Mold Design for Manufacture of Reel Mower Helical Blades

2016 ◽  
Vol 851 ◽  
pp. 255-258
Author(s):  
Chung Ming Tan ◽  
Gin Yei Lin
Keyword(s):  
Computer Aided Engineering ◽  
Roll Forming ◽  
Forming Process ◽  
Compression Process ◽  
New Process ◽  
Computer Aided ◽  
Potential Applications ◽  
Actual Design ◽  
Roll Forming Process ◽  
Deform 3D

This research is focused on the helical blades used in the reel mower machine which uses 5 to 10 helical blades. These blades are normally manufactured using the roll forming process which has certain demerits. This research is done to develop a new process known as compression process for the manufacture of blades using computer aided engineering. To save cost, time as well as waste of material the computerized simulation process is being used. The design of the blade and the die for the compression and modification are done using software SolidWorks. Simulation is performed using software DEFORM-3D. The simulation result and the actual design are compared using software Geomagic. This study also shows the potential applications of computer aided engineering and its benefits in verifying and reinventing the part manufacturing process.

scholarly journals Development of a novel high straining backward extrusion process

2018 ◽  
Vol 190 ◽  
pp. 06001 ◽  
Author(s):  
Qiang Wang ◽  
Zhimin Zhang ◽  
Xubin Li ◽  
Huifang Zhang
Keyword(s):  
Flow Direction ◽  
Effective Strain ◽  
Fibrous Tissue ◽  
Axial Direction ◽  
Extrusion Process ◽  
Backward Extrusion ◽  
New Process ◽  
Processed Sample ◽  
The Difference ◽  
Low Performance

In this study, a new method of backward extrusion is proposed. In this new process, a punch with a movable mandrel was designed. A hollow billet was firstly backward extruded and subsequently upset with the use of the punch after the mandrel returned. The extrusion and upsetting processes were successively executed in order for a higher effective strain to be imposed and a fibrous tissue flow direction to be controlled. In order for the capability of this process to be investigated, experimental and finite element (FE) methods were used. The effective strain of the final part prepared by both the conventional and the new process were compared along the bottom radial and wall axial direction respectively. In the results, it is shown that the plastic strain applied through the processed sample was approximately higher in twice the value of the sample processed via conventional backward extrusion. Consequently, this may improve the mechanical properties and anisotropy of the final products. The difference of the UTS and the TYS between radial and tangential at the bottom was less than 3%.This new process has proven to be promising for parts with a central hole at the bottom production in order for the parts low performance to be improved.

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