An Experimental and Numerical Investigation into Forming Force Reduction in Precision Gear Forging

2014 ◽  
Vol 622-623 ◽  
pp. 165-173 ◽  
Author(s):  
Nicholas J. Politis ◽  
Denis J. Politis ◽  
Catrin Mair Davies ◽  
Jian Guo Lin ◽  
Trevor A. Dean
Keyword(s):  
Peak Load ◽  
Maximum Load ◽  
Fe Model ◽  
Precision Forging ◽  
Die Forging ◽  
Closed Die Forging ◽  
Force Reduction ◽  
Tool Set ◽  
Experimental Trials ◽  
The Cost

A significant factor in the cost of industrial machinery for precision forging is the maximum load required to fully forge the final shape of components. Typically in a precision forging process, the required load increases greatly towards the end of the stroke. This study focuses on reducing the final sharp increase in load encountered in a typical closed die forging setup. A technique of reducing the peak load in the forging of gears is proposed, named the Peripheral Relief (PR) method. A gear forging tool set has been designed and manufactured. A number of experimental trials have been performed using model materials to investigate the force reduction technique. An efficient and simplified FE model has been developed to evaluate the effects of the PR method. The experimental load characteristics are compared to the simulated results. The method has been found, both numerically and experimentally, to significantly reduce the peak load encountered at the end of the forging stroke compared to current closed die forging techniques.

The Present Situation and Developing Trends of Hot Closed-Die Forging

2015 ◽  
Vol 1094 ◽  
pp. 365-368
Author(s):  
Qi Liu ◽  
Xu Guang ◽  
Shi Xuan Sun
Keyword(s):  
Machine Building ◽  
Production Costs ◽  
Research Issues ◽  
Slowing Down ◽  
Research Fields ◽  
Precision Forging ◽  
Die Forging ◽  
Closed Die Forging ◽  
New Ideas ◽  
New Research

Due to its advantages including high quality of the forging parts and low production costs,hot closed-die forging (HCDF) play an essential role in the machine building industry. However, in recent decades, the pace of its development is gradually slowing down. In the hope of drawing up some new ideas about future development of the HCDF, this paper presents a brief overview of it. This study roughly prospects several potential research issues of the HCDF. Some new research fields such as precision forging, combined forging and numerical simulation have been shown. Challenges and possible response to them have been discussed.

Finite Element Analysis and Optimization of Deformation Behavior for Spur Gear Warm Forging Process

2010 ◽  
Vol 148-149 ◽  
pp. 854-858
Author(s):  
Shu Bo Xu ◽  
Cai Nian Jing ◽  
Ke Ke Sun ◽  
Guo Cheng Ren ◽  
Gui Qing Wang
Keyword(s):  
Finite Element ◽  
Spur Gear ◽  
Spur Gears ◽  
Element Analysis ◽  
Helical Gears ◽  
Forging Process ◽  
Precision Forging ◽  
Die Forging ◽  
Closed Die Forging ◽  
Warm Forging

Recent years have therefore seen growing interest in gear precision forging to net-shape form of forge bevel, spur and helical gears, as an alternative to conventional manufacturing. In this paper, gear precision forging processes are simulated by using metal forming finite element code DEFORM-3D. The investigations of gear precision forging processes are conducted with perform forging and final forging processes. The processes of completely closed-die forging, moving-die forging and central divided flow forging processes are investigated for spur gears. The effect of different processes on the distribution of effective stress in the workpieces and forging loads are given. The purpose of this study is to introduce a new method, a so-called floating-relief method which applied to the forging of spur gears. It indicated that the flowing properties of the gear billet have a higher improve than that of conventional forging process. And the forging load obtained by using this new precision forging technology is decline sharply. The floating-relief method for gear precision forging is a sound process in the practical application.

Bulk Deformation

2013 ◽  
pp. 103-161
Keyword(s):  
Hot Extrusion ◽  
High Energy ◽  
Ring Rolling ◽  
Cold Forging ◽  
Bulk Deformation ◽  
High Energy Rate ◽  
Precision Forging ◽  
Die Forging ◽  
Closed Die Forging ◽  
Deformation Processes

Abstract This chapter discusses bulk deformation processes and how they are used to reshape metals and refine solidification structures. It begins by describing the differences between hot and cold working along with their respective advantages. It then discusses various forging methods, including open-die and closed-die forging, hot upset and roll forging, high-energy-rate forging, ring rolling, rotary swaging, radial and orbital forging, isothermal and hot-die forging, precision forging, and cold forging. The chapter also includes information on cold and hot extrusion and drawing operations.

The Precision Forging Experiment of Mg Alloy Drop Forging Using Computer Simulation

2014 ◽  
Vol 1064 ◽  
pp. 175-180
Author(s):  
Mária Kapustová ◽  
Jozef Bílik
Keyword(s):  
Rapid Development ◽  
Production Costs ◽  
Precision Forging ◽  
Ferrous Metals ◽  
Die Forging ◽  
Numeric Simulation ◽  
Closed Die Forging ◽  
Alloy Type ◽  
Non Ferrous Metals ◽  
Increasing Demand

Rapid development of automotive industry brings increasing demand for die forgings made from non-ferrous metals. Market economy stimulates drop forges to produce forged pieces of highest quality and dimension precision with the accent on reduction in production costs. Precision die forging without flash belongs to progressive and economical technologies of die forgings production. This paper describes an experiment of precision forging in closed die of magnesium alloy type AZ 31. Given alloy type Mg-Al-Zn is suitable for bulk forming and is characterized by good hot formability. Achieved results may be applied in practice at production of longitudinal shaped forgings e.g. levers and connecting rods. In order to verify a design of closed die forging technology regarding the lever-shaped forged piece, simulation program MSC.SuperForge was used. Numeric simulation was significantly helpful at optimization of semi-product shape and dimensions and confirmed correct plastic flow of material in closed die cavity. The objective of this contribution was to point out current trends in searching for economical measures at production of die forgings from alloys of non-ferrous metals.

scholarly journals Optimization of Network Carbon Capture and Storage System (CCS) Using Mathematical Approach

2015 ◽  
Vol 9 (7) ◽  
pp. 161
Author(s):  
David Licindo ◽  
Arinne Christin Paramudita ◽  
Renanto Handogo ◽  
Juwari Purwo Sutikno
Keyword(s):  
Carbon Capture ◽  
Storage System ◽  
Carbon Capture And Storage ◽  
Exact Result ◽  
Maximum Load ◽  
Mathematical Approach ◽  
Source To Sink ◽  
Storage Location ◽  
The Cost ◽  
And Storage

Carbon capture and storage (CCS) is one of the technologies to reduce greenhouse gas emissions (GHG) tocapture of CO2 from the flue gas of a power plant that typically use coal as a Source of energy and then store it ina suitable geological storage (in specific locations). In practice, these sites may not be readily available forstorage at the same time that the Sources (GHG producing) are operating which gives rise to multi – periodplanning problems. This study presents a mathematical approach by considering constraints limit flowratereceived by Sink, various time availability of Sink and Source and calculation with the purpose to determine theminimum cost network which is getting the maximum load that is exchanged from Source to Sink. Illustrativecase studies are given to demonstrate the application of mathematical models to obtained with the exact result ofthe exchange network from Source to Sink. Derived from network obtained from the calculation of theMaximum Load Source to Sink and results may vary in accordance with the limitations that exist in themathematical model. The case study has been prepared with 2 cases, first 6 Source and 3 Sink with value ofSource Load is greater than the amount available on the Sink. Also, second case is 2 Source and 5 Sinkwithvalue of Source Load is smaller than the amount available on the Sink. In addition, Case Studies tominimize the cost of pipeline construction and distribution of CO2 by plant and storage location determination inJava. Flowrate restriction factor that goes into Sink, Source and Sink establishment time and cost are taken intoaccount can affect the networks that can be exchanged from the Source to the Sink.

scholarly journals A review of force reduction methods in precision forging axisymmetric shapes

2018 ◽  
Vol 97 (5-8) ◽  
pp. 2809-2833 ◽  
Author(s):  
Denis J. Politis ◽  
Nicholas J. Politis ◽  
Jianguo Lin ◽  
Trevor A. Dean
Keyword(s):  
Precision Forging ◽  
Reduction Methods ◽  
Force Reduction

Slip Line Field Analysis of a Simple Plane Strain Closed-Die Forging

1989 ◽  
Vol 203 (2) ◽  
pp. 91-99
Author(s):  
M V Srinivas ◽  
P Alva ◽  
S K Biswas
Keyword(s):  
Velocity Field ◽  
Plane Strain ◽  
Slip Line ◽  
Field Analysis ◽  
Line Field ◽  
Slip Line Field ◽  
Die Forging ◽  
Closed Die Forging ◽  
Cavity Filling ◽  
Single Cavity

A slip line field is proposed for symmetrical single-cavity closed-die forging by rough dies. A compatible velocity field is shown to exist. Experiments were conducted using lead workpiece and rough dies. Experimentally observed flow and load were used to validate the proposed slip line field. The slip line field was used to simulate the process in the computer with the objective of studying the influence of flash geometry on cavity filling.

Three-Dimensional Analysis of Closed-Die Forging Processes: Part 1: Formulation

1989 ◽  
Vol 203 (1) ◽  
pp. 33-37 ◽  
Author(s):  
C F Lugora ◽  
A N Bramley
Keyword(s):  
Theoretical Model ◽  
Energy Dissipation ◽  
Metal Flow ◽  
Three Dimensional ◽  
Total Rate ◽  
Die Forging ◽  
Closed Die Forging ◽  
Proposed Model ◽  
Optimum Velocity ◽  
Forging Load

In this series of papers, a theoretical model based on the upper bound elemental technique is presented for prediction of forging load and metal flow in three-dimensional closed-die forging processes. Three basic elements are introduced in order to partition a forging into simple elementary regions. An optimum velocity distribution within the forging is obtained by minimizing the total rate of energy dissipation using a simplex optimizing procedure. Applications of the proposed model are discussed in Part 2.

The Optimization Model of Wind Power and Thermal Power Jointly Run under the TOU Price

2013 ◽  
Vol 772 ◽  
pp. 705-710
Author(s):  
Li Wei Ju ◽  
Zhong Fu Tan ◽  
He Yin ◽  
Zhi Hong Chen
Keyword(s):  
Wind Power ◽  
Optimization Model ◽  
Unit Commitment ◽  
Thermal Power ◽  
Peak Load ◽  
Electricity Demand ◽  
Environmental Benefits ◽  
Power Company ◽  
The Cost ◽  
Pollution Emissions

In order to be able to absorb the abandoned wind, increasing wind-connect amount, the paper study the way of wind power, thermal power joint run and puts forward wind power, thermal power joint run optimization model based on the energy-saving generation dispatching way under the environment of TOU price and the target of minimizing the cost of coal-fired cost, unit commitment and pollution emissions. The numerical example finds, the TOU price can realize the goal of peak load shifting, increasing the electricity demand in the low load and reducing electricity demand in the peak load. The model can increase the amount of wind-connect grid, absorb the abandoned wind, reduce the use of coal-fired units under the environment, increase the average electricity sales price and profit of Power Company. Therefore, the model has significant economical environmental benefits

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