Energy-Efficient Solid Forward Extrusion through Hybridization Based on Process-Integrated Resistance Heating

2013 ◽  
Vol 554-557 ◽  
pp. 620-629 ◽  
Author(s):  
Michael Terhorst ◽  
Fritz Klocke ◽  
Stefan Niebes ◽  
Fabian Schongen ◽  
Patrick Mattfeld
Keyword(s):  
Energy Efficient ◽  
Process Integration ◽  
Numerical Algorithms ◽  
Numerical Approach ◽  
Extrusion Process ◽  
Resistance Heating ◽  
Forming Process ◽  
Workpiece Material ◽  
Forward Extrusion ◽  
Deform 2D

In this paper a hybridized solid forward extrusion process is proposed that uses a process-integrated resistance heating for the energy-efficient heating of the workpiece material in order to avoid the occurrence of chevron cracks. As for the process-integration of the resistance heating two variations are regarded: the preheating of the wrought material prior to the forming process as well as a resistance heating concurrent with the extrusion process. Based on a three-shouldered solid forward extrusion of Cf53 with emerging chevron cracks the broad temperature interval for crack elimination is derived from experiments where the wrought material is preheated in a furnace. With this derived temperature a numerical approach for the dimensioning of a resistance heating of both prior to the forming process and during extrusion is shown. The approach is based on solving the Fourier heat transfer equation using both numerical algorithms in MATLAB and finite element method (FEM) in Deform-2D. In a final step the two scenarios heating prior to and during the extrusion process are evaluated in terms of their energy-efficiency using FEM.

scholarly journals Process chain for the manufacture of hybrid bearing bushings

2021 ◽  
Vol 15 (2) ◽  
pp. 137-150
Author(s):  
Susanne Elisabeth Thürer ◽  
Anna Chugreeva ◽  
Norman Heimes ◽  
Johanna Uhe ◽  
Bernd-Arno Behrens ◽  
...  
Keyword(s):  
Extrusion Process ◽  
Steel Tube ◽  
Case Hardening ◽  
Process Chain ◽  
Forming Process ◽  
Die Forging ◽  
Material Contact ◽  
Hybrid Bearing ◽  
Case Hardening Steel ◽  
Tailored Forming

AbstractThe current study presents a novel Tailored Forming process chain developed for the production of hybrid bearing bushings. In a first step, semi-finished products in the form of locally reinforced hollow profiles were produced using a new co-extrusion process. For this purpose, a modular tool concept was developed in which a steel tube made of a case-hardening steel, either C15 (AISI 1015) or 20MnCr5 (AISI 5120), is fed laterally into the tool. Inside the welding chamber, the steel tube is joined with the extruded aluminum alloy EN AW-6082. In the second step, sections from the compound profiles were formed into hybrid bearing bushings by die forging. In order to set the required forming temperatures for each material—aluminum and steel—simultaneously, a tailored heating strategy was developed, which enabled successful die forging of the hybrid workpiece to the desired bearing bushing geometry. Using either of the case-hardening steels in combination with aluminum, this novel process chain made it possible to produce intact hybrid bearing bushings, which showed both macroscopically and microscopically intimate material contact inside the compound zone.

Milling Curves Influence in Ring Rolling Processes

2014 ◽  
Vol 622-623 ◽  
pp. 956-963 ◽  
Author(s):  
Luca Giorleo ◽  
Elisabetta Ceretti ◽  
Claudio Giardini
Keyword(s):  
Numerical Approach ◽  
The Other ◽  
Ring Rolling ◽  
Roll Speed ◽  
Forming Process ◽  
Industrial Case Study ◽  
Industrial Environment ◽  
Ring Shape ◽  
Deformation Processes

Ring Rolling is a complex hot forming process used for the production of shaped rings, seamless and axis symmetrical workpieces. The main advantage of workpieces produced by ring rolling, compared to other technological processes, is given by the size and orientation of grains, especially on the worked surface which give to the final product excellent mechanical properties. In this process different rolls (Idle, Axial, Guide and Driver) are involved in generating the desired ring shape. Since each roll is characterized by a speed law that can be set independently by the speed law imposed to the other rolls, an optimization is more critical compared with other deformation processes. Usually, in industrial environment, a milling curve is introduced in order to correlate the Idle and Axial roll displacement, however it must be underlined that different milling curves lead to different loads and energy for ring realization. In this work an industrial case study was modeled by a numerical approach: different milling curves characterized by different Idle and Axial roll speed laws (linearly decreasing, constant, linearly increasing) were designed and simulated. The results were compared in order to identify the best milling curve that guarantees a good quality ring (higher diameter, lower fishtail) with lower loads and energy required for manufacturing.

Experimental Study of a Full Forward Extrusion Process from Metal Strip

2012 ◽  
Vol 504-506 ◽  
pp. 587-592 ◽  
Author(s):  
Marion Merklein ◽  
Tommaso Stellin ◽  
Ulf Engel
Keyword(s):  
Extrusion Process ◽  
Metal Strip ◽  
Raw Material ◽  
High Rate ◽  
Process Chain ◽  
Forward Extrusion ◽  
Bulk Forming ◽  
Material Conditions ◽  
Set Up ◽  
Tooling System

A high rate of production of complex microparts is increasingly required by fields like electronics and micromechanics. Handling is one of the main problems, limiting those forming processes of small metal components consisting of multiple forming stages. A forming chain in which a metal strip acts both as raw material and support of the workpiece through the different stages of the process, is seen as a solution that radically simplifies the positioning of microparts. Each workpiece stays connected to the strip through all the forming steps, being separated just at the end of the process chain. In this work, a tooling system for the bulk forming from copper strips has been set up and employed in a full forward extrusion process of a micro-billet. The same die, with a diameter of 1 mm, has been used with three different strip thicknesses (1, 2 and 3 mm) and three different material conditions. The use of thinner and hard-as-rolled strips has resulted in achieving a higher ratio of the billet length to strip thickness.

scholarly journals Experimental Investigation of the Equal Channel Forward Extrusion Process

Metals ◽  
2015 ◽  
Vol 5 (1) ◽  
pp. 471-483 ◽  
Author(s):  
Mahmoud Ebrahimi ◽  
Faramarz Djavanroodi ◽  
Sobhan Tiji ◽  
Hamed Gholipour ◽  
Ceren Gode
Keyword(s):  
Experimental Investigation ◽  
Extrusion Process ◽  
Forward Extrusion

Hot Spline Forming of Ultra-High Strength Steel Gear Drum Using Resistance Heating

2014 ◽  
Vol 622-623 ◽  
pp. 201-206 ◽  
Author(s):  
Kenichiro Mori ◽  
Tomoyoshi Maeno ◽  
Shohei Nakamoto
Keyword(s):  
Deep Drawing ◽  
High Strength Steel ◽  
Side Wall ◽  
High Strength ◽  
Axial Direction ◽  
Resistance Heating ◽  
Sectional Area ◽  
Forming Process ◽  
Cross Sectional ◽  
Ultra High Strength Steel

A hot spline forming process of die-quenched gear drums using resistance heating of a side wall of a cup formed by cold deep drawing and ironing was developed. The side wall having uniform cross-sectional area is resistance-heated by passage of the current in the axial direction, the heated side wall of the drawn cup is ironed and is finally die-quenched. The gear drum was successfully formed and the hardness was between 400 and 500 HV. Not only the formability was improved but also the formed dram was hardly oxidised because of rapid resistance heating.

Metaheuristic Approaches for Extrusion Manufacturing Process

2018 ◽  
pp. 43-56 ◽  
Author(s):  
Pauline Ong ◽  
Desmond Daniel Vui Sheng Chin ◽  
Choon Sin Ho ◽  
Chuan Huat Ng
Keyword(s):  
Extrusion Process ◽  
Flower Pollination Algorithm ◽  
Trial And Error ◽  
Optimal Parameters ◽  
Flower Pollination ◽  
Forward Extrusion ◽  
Comparable Performance ◽  
Trial And Error Method ◽  
Nature Inspired Algorithms ◽  
Error Method

Optimization, basically, is a method used to find solutions for a particular problem without neglecting the existing boundaries or limitations. Flower Pollination Algorithm (FPA) is one of the recently developed nature inspired algorithms, based on the intriguing process of flower pollination in the world of nature. The main aim of this study is to utilize FPA in optimizing cold forward extrusion process in order to obtain optimal parameters to produce workpiece with the minimum force load. It is very important to find the most optimal parameters for an extrusion process in order to prevent waste from happening due to trial and error method in determining the optimal parameters and thus, FPA is used to replace the traditional trial and error method to optimize the cold forward extrusion process. The optimization performance of the FPA is then compared with the particle swarm optimization (PSO), in which the FPA shows comparable performance in this regard.

scholarly journals High productivity micro rotary swaging

2018 ◽  
Vol 190 ◽  
pp. 15002 ◽  
Author(s):  
Eric Moumi ◽  
Marius Herrmann ◽  
Christian Schenck ◽  
Bernd Kuhfuss
Keyword(s):  
Material Flow ◽  
Process Variations ◽  
Main Process ◽  
Forming Process ◽  
Workpiece Material ◽  
High Productivity ◽  
Rotary Swaging ◽  
Micro Parts ◽  
Intensive Investigation ◽  
Clamping Device

Rotary swaging is an incremental forming process with two main process variations plunge and infeed rotary swaging. With plunge rotary swaging, the diameter is reduced within a limited section whereas the infeed rotary swaging enables a diameter reduction over the entire workpiece length. The process is now subject to intensive investigation for manufacturing of micro parts. By increasing the process speed, failures occur particularly due to inappropriate material flow. In plunge rotary swaging, the workpiece material can flow radially into the gap between the dies and thus the workpiece quality suffers. In infeed rotary swaging the workpiece material flows against the feeding direction and can provoke bending or braking of the workpiece. Therefore, additional measures to control both the radial and the axial material flow to enable high productivity micro rotary swaging are investigated. The radial material flow during plunge rotary swaging can be controlled by elastic intermediate elements that enable an increase of productivity by factor three. A spring-loaded clamping device that enables an increase of the productivity by factor four can temporarily buffer the axial material flow in infeed rotary swaging against the feeding direction.

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