Sensitivity Analysis of Process Parameters for Developing an Improved Open Die Forging Process

2014 ◽  
Vol 622-623 ◽  
pp. 231-238
Author(s):  
Yu Feng Cheng ◽  
Xiao Guang Yang ◽  
Qi Lu ◽  
Chao Voon Samuel Lim ◽  
Ai Jun Huang
Keyword(s):  
Sensitivity Analysis ◽  
Process Parameters ◽  
Effective Strain ◽  
Hot Forging ◽  
Forging Process ◽  
Analysis Process ◽  
Die Forging ◽  
Experiment Method ◽  
Experimental Process ◽  
Open Die Forging

Open die hot forging has a wide industrial application on deforming ingot into billet with desired dimension and qualified internal microstructure. An example open die forging process of Ti-6Al-4V ingot is selected herein. A 3D FE-based numerical method was used to investigate the open die forging process with respect to the real working conditions. The simulation results were validated by the collected experimental process parameters from the forging system. Moreover, design of experiment method is adopted regarding the variation of process parameters to reveal the effects of critical factors on product deformation and quality characteristics. Results show that the process parameters including press speed, feed and reduction has significant effect on the workpiece deformation and effective strain which represents the forged billet formability and quality. Improved process parameters method is suggested with respect to the experienced benchmark based on the sensitivity analysis. Keywords: Open die forging; Ti-6Al-4V alloy; Sensitivity analysis; Process parameter; Numerical simulation;

Analysis on Void Closure Behavior during Hot Open Die Forging

2007 ◽  
Vol 26-28 ◽  
pp. 69-72 ◽  
Author(s):  
Young Seon Lee ◽  
Y.C. Kwon ◽  
Yong Nam Kwon ◽  
Jung Hwan Lee ◽  
S.W. Lee ◽  
...  
Keyword(s):  
Numerical Analysis ◽  
Effective Strain ◽  
Fem Analysis ◽  
Void Closure ◽  
X Ray ◽  
Die Forging ◽  
Before And After ◽  
Measured Flow ◽  
Flow Stress Data ◽  
Open Die Forging

Internal voids have to be eliminated for defect-free in some open die forging. The FEM analysis is performed to investigate the overlap defect of cast ingots during cogging stage. The measured flow stress data were used to simulate the cogging process of cast ingot using the practical material properties. Also the numerical analysis of void closure is performed by using the DEFORMTM-3D. The calculated results of void closure behavior are compared with the measured results before and after upsetting, which are scanned by the X-ray scanner. From this result, the criteria for deformation amounts effect on the void closure were estimated into effective strain of 0.6 by the comparison of practical experiment and numerical analysis.

scholarly journals An Analysis Of The Industrial Forging Process Of Flange In Order To Reduce The Weight Of The Input Material

2015 ◽  
Vol 60 (2) ◽  
pp. 849-853 ◽  
Author(s):  
Z. Gronostajski ◽  
M. Hawryluk ◽  
M. Kaszuba ◽  
G. Misiun ◽  
A. Niechajowicz ◽  
...  
Keyword(s):  
Hot Forging ◽  
Industrial Process ◽  
Maximum Load ◽  
Operating Conditions ◽  
Production Costs ◽  
Forging Process ◽  
Die Forging ◽  
Input Material ◽  
Infrared Measurements ◽  
Optimum Direction

Abstract This paper presents an analysis of the industrial process of hot forging a flange. The authors developed several thermomechanical models of the forging process for which they carried out computer simulations using the MSC.Marc 2013 software. In the Jawor Forge flanges with a neck are manufactured by hot forging in crank presses with a maximum load of 25 MN. The input material, in the form of a square bar, is heated up to a temperature of 1150°C and then formed in three operations: upsetting, preliminary die forging and finishing die forging. The main aim of the studies and the numerical analyses, in which the geometry of the tools would be modified, was to maximally reduce the amount of the input material taking into account the capabilities of the Jawor Forge, and consequently to significantly reduce the production costs. Besides the Forge’s equipment resources, the main constraint for modifications was the flange-with-neck forging standard which explicitely defines the tolerances for this element. The studies, which included numerical modelling, infrared measurements and technological tests, consisted in changing the geometry of the tools and that of the forging preform. As a result, the optimum direction for modifications aimed at reducing the mass of the input material was determined. The best of the solutions, making it possible to produce a correct forging in the Jawor Forge operating conditions, were adopted whereby the weight of the preform was reduced by 6.11%. Currently research is underway aimed at the application of the proposed and verified modifications to other flange forgings.

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.

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 Interactions Between Dynamic Softening and Strengthening Mechanisms During Hot Forging of a High-Strength Steel

2021 ◽  
Vol 7 ◽  
Author(s):  
Makarim Khan ◽  
Davood Shahriari ◽  
Mohammad Jahazi ◽  
Jean-Benoit Morin
Keyword(s):  
Electron Microscopy ◽  
Dynamic Recrystallization ◽  
High Strength Steel ◽  
True Strain ◽  
Hot Forging ◽  
High Strength ◽  
Actual Process ◽  
Dynamic Precipitation ◽  
Die Forging ◽  
Open Die Forging

Open-die forging is a critical step in the manufacture of large numbers of components used in the transportation and energy industries. Dynamic recrystallization, dynamic transformation, and dynamic precipitation take place during the hot deformation process and significantly affect microstructure conditioning, which ultimately influences the service properties of the component. In the present work, using a Gleeble 3800 thermomechanical simulator, the open-die forging of a large-size ingot made of a modified AISI 6140 medium carbon high-strength steel is investigated. Deformation temperatures ranging from 950°C to 1,250°C and strain rates ranging from 0.01 to 1 s−1, representative of the actual process, are considered in the analysis. The generated true stress–true strain curves are used as a basis for the development of a constitutive model predicting the occurrence of softening and strengthening phenomena as a function of thermomechanical conditions. The corresponding activation energy is determined to be about 374 kJ mol−1 and is compared against the values reported in the literature for other high-strength steels. Dynamic recrystallization kinetics is studied using the t50 model, and the influence of temperature and strain rate is quantified and discussed. The interaction between dynamic precipitation and dynamic recrystallization is discussed, and the deformation conditions under which such interactions occur are determined. The thermomechanical results are validated by microstructure examination, including laser confocal microscopy, field emission scanning electron microscopy, transmission electron microscopy, and energy-dispersive spectroscopy. The present study focuses on reproducing the deformation cycle applied during the open-die forging process of a vanadium-containing high-strength steel used in the industry with special attention to the interaction between dynamic recrystallization and precipitation processes.

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