Study of Isothermal Split-Die Precision Forging Process of High-Strength Aluminum Alloy Complex-Shape Forgings

2014 ◽  
Vol 941-944 ◽  
pp. 1761-1768
Author(s):  
Jun Lin ◽  
Feng Kang ◽  
Chuan Kai Hu ◽  
Qiang Chen ◽  
Zu De Zhao
Keyword(s):  
Complex Shape ◽  
Dimensional Accuracy ◽  
High Strength ◽  
Hydraulic Press ◽  
Geometric Configuration ◽  
Forging Process ◽  
Precision Forging ◽  
Die Forging ◽  
Calculation Results

Taking the geometric configuration of complex-shape forging into account, the isothermal split-die forging method, which is one multi-way die forging technology and can be operated on the general hydraulic press, is employed. The temperatures of billed and dies are 420°C and 380°C in the isothermal forging process. The coupled thermo-mechanical finite element method (FEM) is used to analyze the forging process. FEM calculation results show several folds had been formed in the final forging process due to unreasonable geometric configuration of preform. The folds mechanism is that direction of velocities become cross on the surface of billet, and the folds can be avoided if the direction would be kept convex. And then the preform is redesigned. A set of isothermal precision forming equipment is designed and manufactured. The experimental results verify the selected process and preform configuration. And all of the hardness, dimensional accuracy and surface quality of the forgings obtained by the equipments satisfy the requirements.

scholarly journals Effect of Technical Quality of Thermomechanical Die Forging of AA2099 Alloy

2014 ◽  
Vol 59 (3) ◽  
pp. 997-1003
Author(s):  
A. Łukaszek-Sołek
Keyword(s):  
Numerical Modelling ◽  
Complex Shape ◽  
True Strain ◽  
Process Conditions ◽  
Technical Quality ◽  
Compression Tests ◽  
Forging Process ◽  
Die Forging ◽  
Microstructure Examination

Abstract The paper presents the results of investigations of a multicomponent third-generation aluminium alloy, classified as AA2099. The actual forging conditions were determined basing on the assessment of the quality of side surface of specimens subjected to compression in Gleeble 3800 simulator and on flow curves of the alloy, as well as numerical modelling of forging process performed with application of QForm 3D v.7 software. Compression tests were realized at temperatures 400-500 °C, with a strain rate of 0.001-100 s-1, up to a specified constant true strain value of 0.9. Microstructure examination in as-delivered state was performed with application of Leica DM 4000M optical microscope. The obtained results of isothermal deformation of specimens were correlated with the analysis of a characteristic layered pancake-type microstructure. The simulation of die forging of a complex-shape forging (high-current contact tip used in power engineering) at the temperature 500 °C, was performed. The shape of a forging makes it possible to fully analyse the influence of thermomechanical process conditions on technical quality of a product. The simulation of forging process showed full correctness of material flow, with no signs of instability. At the same time, the analysis of investigations allowed to prepare and realize the industrial forging trials for a forging of a very complex shape, in a single step, at the temperature 500 °C, with application of thermomechanical treatment. The forging attained high quality of shape and surface. Directional specimens were taken, in order to be subjected to microstructure examination and hardness testing. The data obtained from industrial tests, combined with the results of testing using Gleeble simulator as well as from numerical modelling, make up the guidelines for mechanical processing of AA2099 alloy at the temperatures 470-500 °C.

Die Forging of High-Strength Magnesium Alloys – the Structure and Mechanical Properties in Different Heat Treatment Conditions / Kucie Matrycowe Wysokowytrzymałych Stopów Mg – Struktura I Własciwosci Mechaniczne W Róznych Stanach Obróbki Cieplnej

2013 ◽  
Vol 58 (1) ◽  
pp. 127-132 ◽  
Author(s):  
B. Płonka ◽  
M. Lech-Grega ◽  
K. Remsak ◽  
P. Korczak ◽  
A. Kłyszewski
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Magnesium Alloys ◽  
High Strength ◽  
Hydraulic Press ◽  
Forging Process ◽  
Fine Grained ◽  
Die Forging ◽  
Treatment Conditions ◽  
Fine Grained Structure

The object of this study was to develop parameter of the die forging process, such as feedstock temperature and to investigate her impact on the structure and mechanical properties of magnesium alloys in different heat treatment conditions. Tests were carried out on a 2,5MN maximum capacity vertical hydraulic press using forgings of sample (model) shapes. Then, based on the results obtained in previous work, research was carried out to develop for items forged from magnesium alloys the parameters of heat treatment to the T5 and T6 condition in the context of achieving possibly homogeneous and fine-grained structure and, consequently, high mechanical properties.

Co-Simulation Research of the Balancing Control of the Moving Beam of a Heavy Hydraulic Press During the Die Forging Process

2017 ◽  
Author(s):  
Wenzhu Wang ◽  
Dong Du ◽  
Rendong Wu ◽  
Chaolong Yuan ◽  
Baohua Chang
Keyword(s):  
Control Process ◽  
Virtual Prototype ◽  
Hydraulic Press ◽  
Heavy Duty ◽  
Eccentric Load ◽  
Forging Process ◽  
Die Forging ◽  
Moving Beam ◽  
Synchronous Rectification ◽  
Balancing Control

A virtual prototype of the moving beam balancing system of a heavy-duty hydraulic press working under die forging function is built with Adams, AMESim and Simulink, and the balancing control process is analyzed using this prototype. The moving beam of the heavy-duty hydraulic press may tilt due to the eccentric load during the die forging processing, and thus affect the forging quality and the safety of the press. So it is necessary to research the beam balancing control process. Compared to the traditional methods based on simplified mathematical models, virtual prototype technology can obtain a co-simulation model, avoid tedious formula derivation and solving work, and save test time and cost. Based on the analysis of the working principle of balancing system, this paper establishes a dynamical model of the moving beam, a hydraulic circuit model of the single balancing system and a controller model using Adams, AMESim and Simulink, respectively. Then a virtual prototype is built using the three models via co-simulation interface files. The eccentric load signal is constructed in AMESim according to the variation of eccentric load during die forging process. By adjusting the controller parameters, the rapid balancing of the moving beam under eccentric load conditions is realized, and high precision of dynamic balancing and steady equilibrium is obtained. The simulation results show that the single balancing unit can achieve effective balancing of the moving beam, and the co-simulation analysis method based on the virtual prototype built with Adams, AMESim and Simulink is feasible in the research of the synchronous rectification of the moving beam. This work is a useful exploration in the research of synchronous rectification of moving beams.

Simulation and Microstructure Predict during Hot Die-Forging of Cast Mg-7.0Al-0.2Zn Magnesium Alloy

2010 ◽  
Vol 152-153 ◽  
pp. 1293-1296
Author(s):  
Li Hong Wu
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Magnesium Alloy ◽  
Strain Distribution ◽  
Forging Process ◽  
Die Forging ◽  
Comparison Results ◽  
Hot Die Forging ◽  
Good Agreement

Employing the dies for aluminum alloy parts, the hot die-forging forming and numerical simulation of semi-continuous casting Mg-7.0Al-0.4Zn (AZ70) were carried out. It was indicated that AZ70 has a worse fluidity during forging and is consequently difficult to fill fully compared to aluminum alloys. The microstructure of the AZ70 forgings is in good agreement with the strain distribution generated by simulation, and strain distribution can predict the microstructure evolution. The comparison results can give a guideline on developing forging process and controlling forgings quality of the AZ70 alloy.

scholarly journals Analysis of Void Closure during Open Die Forging Process of Large Size Steel Ingots

2016 ◽  
Vol 716 ◽  
pp. 579-585 ◽  
Author(s):  
Nathan Harris ◽  
Davood Shahriari ◽  
Mohammad Jahazi
Keyword(s):  
Strain Rate ◽  
High Strength Steel ◽  
Volumetric Strain ◽  
High Strength ◽  
Material Model ◽  
Void Closure ◽  
Forging Process ◽  
Large Size ◽  
Die Forging ◽  
Open Die Forging

Large size forged ingots, made of high strength steel, are widely used in aerospace, transport and energy applications. The presence of internal voids in the as-cast ingot may significantly affect the mechanical properties of final products. Thus, such internal defects must be eliminated during first steps of the open die forging process. In this paper, the effect of in-billet void positioning on void closure throughout the ingot breakdown process and specifically the upsetting step in a large ingot size steel is quantitatively investigated. The developed Hansel-Spittel material model for new high strength steel is used in this study. The ingot forging process (3D simulation) was simulated with Forge NxT 1.0® according to existing industrial data. A degree of closure of ten virtual existing voids was evaluated using a semi-analytical void closure model. It is found that the upsetting process is most effective for void closure in core regions and central upper billet including certain areas within the dead metal zone (DMZ). The volumetric strain rate is determined and two types of inertial effects are observed. The dependence of void closure on accumulated equivalent deformation is calculated and discussed in relation to void in-billet locations. The original combination of information from both relative void closure and the volumetric strain rate provides a way to optimize the forging process in terms of void elimination.

scholarly journals Prediction of the parameters and the hot open die elongation forging process on an 80 MN hydraulic press

2021 ◽  
Vol 11 (1) ◽  
pp. 528-534
Author(s):  
Ryszard Dindorf ◽  
Jakub Takosoglu ◽  
Piotr Wos
Keyword(s):  
Dynamic Model ◽  
Predictive Control ◽  
Material Properties ◽  
Hydraulic Press ◽  
Generalized Predictive Control ◽  
Main Task ◽  
Forging Process ◽  
Die Forging ◽  
Open Die Forging ◽  
Forging Press

Abstract The main task of the study was to develop and implement predictive control in the hot open die forging process of heavy, large, and hard deformable steel forgings on an 80 MN hydraulic press at the Forged Products Department (FPD) of Celsa Huta Ostrowiec (CHO). The predicted hot flow stresses and the predicted deformation/forging forces as a function of the parameters of the elongation forging process were determined. The predicted parameters of the forging process were included in the dynamic model of the hydraulic forging press. Generalized predictive control (GPC) algorithm of the hot open-die forging process on the hydraulic press was developed. The use of predictive control solved the uncertainty of the hot open forging process, which depends on the dimensions, shapes, and material properties of the forgings, as well as the parameters of the hydraulic press and forging tools.

A Design in the Optimal Precision Forging Process about Transmission Shaft Flange Yoke

2010 ◽  
Vol 44-47 ◽  
pp. 2832-2836
Author(s):  
Ying Tong
Keyword(s):  
Complex Shape ◽  
Hot Forging ◽  
Element Model ◽  
Decision Making Process ◽  
Forming Process ◽  
Forging Process ◽  
Precision Forging ◽  
Transmission Shaft ◽  
Forming Defects ◽  
Hot Forging Process

The rigid-visco-plastic finite element model for the hot forging process of transmission shaft flange yoke was established, and two forging schemes of different male die shapes were simulated. As for the present forming process, the forming defects were indentified and analyzed. Based on the simulating results the decision-making process was obtained, and a preforming die and a final forming die with proper structures and longer life were designed. The transmission shaft flange yoke part produced by this process is excellent in dimension tolerance and mechanical property. This process is profitable reference for producing the similar type of forks with complex shape.

A study of a new screw press forging process for producing aircraft drop forgings made of magnesium alloy AZ61A

2018 ◽  
Vol 90 (3) ◽  
pp. 559-565 ◽  
Author(s):  
Andrzej Gontarz ◽  
Krzysztof Drozdowski ◽  
Anna Dziubinska ◽  
Grzegorz Winiarski
Keyword(s):  
Magnesium Alloy ◽  
Production Efficiency ◽  
Ferrous Metal ◽  
Screw Press ◽  
Manufacturing Costs ◽  
Content Type ◽  
Fundamental Parameters ◽  
Forging Process ◽  
Die Forging

Purpose The aim of this study is to develop a die forging process for producing aircraft components made of magnesium alloy AZ61A using a screw press. Design/methodology/approach The proposed forging technique has been developed based on the results of a numerical and experimental research. The required forging temperature has been determined by upsetting cylindrical specimens on a screw press to examine both plasticity of the alloy and the quality of its microstructure. The next stage involved performing numerical simulations of the designed forging processes for producing forgings of a door handle and a bracket, both made of magnesium alloy AZ61A. The finite element method based on simulation programme, Deform 3D has been used for numerical modelling. The numerical results revealed that the forgings are free from material overheating and shape defects. In addition to this, the results have also helped determine the regions that are the most prone to cracking. The final stage of the research involved performing forging tests on a screw press under industrial conditions. The forgings of door handles and brackets were made, and then these were tested for their mechanical and structural properties. The results served as a basis for assessing both the viability of the designed technique and the quality of the produced parts. Findings The experimental results demonstrate that aircraft components made of magnesium alloy AZ61A can be produced by die forging on screw presses. The results have been used to determine the fundamental parameters of the process such as the optimum forging temperature, the method of tool heating, the way of cooling parts after the forging process, and the method of thermal treatment. The results of the mechanical and structural tests confirm that the products meet the required quality standards. Practical implications The developed forging technique for alloy AZ61A has been implemented by the forging plant ZOP Co. Ltd in Swidnik (Poland), which specializes in the manufacturing of aircraft components made of non-ferrous metal alloys. Originality/value Currently, the global tendency is to forge magnesium alloys (including alloy AZ61A) on free hydraulic presses using expensive die-heating systems. For this reason, the production efficiency of such forging processes is low, while the manufacturing costs are high. The proposed forging technique for alloy AZ61A is an innovative method for producing forgings using relatively fast and efficient machines (screw presses). The proposed forging method can be implemented by forging plants equipped with standard stocks of tools, which increases the range of potential manufacturers of magnesium alloy products. In addition, this technology is highly efficient and ensures reduced manufacturing costs.

scholarly journals Effect of Selective Laser Melting Process Parameters on the Quality of Al Alloy Parts: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy

Materials ◽  
2018 ◽  
Vol 11 (12) ◽  
pp. 2343 ◽  
Author(s):  
Ahmed Maamoun ◽  
Yi Xue ◽  
Mohamed Elbestawi ◽  
Stephen Veldhuis
Keyword(s):  
Surface Roughness ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
Dimensional Accuracy ◽  
High Strength ◽  
Melting Process ◽  
Al Alloys ◽  
Al Alloy ◽  
Laser Melting

Additive manufacturing (AM) of high-strength Al alloys promises to enhance the performance of critical components related to various aerospace and automotive applications. The key advantage of AM is its ability to generate lightweight, robust, and complex shapes. However, the characteristics of the as-built parts may represent an obstacle to the satisfaction of the parts’ quality requirements. The current study investigates the influence of selective laser melting (SLM) process parameters on the quality of parts fabricated from different Al alloys. A design of experiment (DOE) was used to analyze relative density, porosity, surface roughness, and dimensional accuracy according to the interaction effect between the SLM process parameters. The results show a range of energy densities and SLM process parameters for AlSi10Mg and Al6061 alloys needed to achieve “optimum” values for each performance characteristic. A process map was developed for each material by combining the optimized range of SLM process parameters for each characteristic to ensure good quality of the as-built parts. This study is also aimed at reducing the amount of post-processing needed according to the optimal processing window detected.

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