Numerical Analysis on Precision Forging of 7A09 Aluminum Impeller

2009 ◽  
Vol 628-629 ◽  
pp. 535-540 ◽  
Author(s):  
Wei Wei Wang ◽  
Jian Li Song ◽  
Fei Han ◽  
Shou Jing Luo
Keyword(s):  
Flow Line ◽  
Metal Flow ◽  
Forming Process ◽  
Precision Forging ◽  
Die Structure ◽  
Forming Characteristics ◽  
Forging Die ◽  
Deform 3D ◽  
Forging Load ◽  
Good Flow

Numerical simulation and test forming of the isothermal precision forging of an impeller was carried out. The forming processes were simulated with DEFORM-3D to obtain the forming characteristics and metal flow pattern. It indicated that the impeller can be forged by the method of isothermal-forging, and the deforming process can be divided into 3 stages. The forming of blades was depended on the extrusion of materials. During the forming, uneven deformation was existed in the billet, especially in the field of the blade root. The forging load was increased rapidly during the later stage of the forming process, and the maximum forging load was about 2961kN. According to the simulations, the die structure and the billet dimension were determined, the forging die was designed and manufactured, and the precision forgings of the impeller were produced successfully. Both of the simulation and the test forming indicated that the impeller forging could be performed with the assembled structure die and the isothermal extruding forming style satisfactorily. The ideal parameters to produce the precision forgings of the impeller are: a forging temperature of 450°C and a punch speed of 1mm/s. Under these conditions, the forgings of the impeller can be produced with full blades, smooth outer surface and good flow line, which can meet the requirements of the precision forging of impellers.

Numerical and Experimental Studies of the Precision Forging of a Screw Propeller

2009 ◽  
Vol 419-420 ◽  
pp. 429-432
Author(s):  
Wei Wei Wang ◽  
Fei Han ◽  
Shou Jing Luo
Keyword(s):  
Material Flow ◽  
Flow Line ◽  
Effective Strain ◽  
Experimental Studies ◽  
Forming Process ◽  
Forming Load ◽  
Precision Forging ◽  
Screw Propeller ◽  
Forging Die ◽  
Forging Load

The isothermal precision forging of a screw propeller was studied by means of numerical simulation and experimental forming. The deforming processes of the billet under two different forging patterns were discussed. The distributions of the flow line, the effective strain within the billet and the variation of the forging load during the forming process were analyzed. Results showed that there was a great difference of the effective strain existing between the blades and the wheel hub. The material flow and the distribution of deformation can be improved obviously by adding a core punch on the die. The distribution of deformation and forming load can be changed and controlled by adjusting the process parameters. The forging die was designed and manufactured according to the simulation results and perfect precision forgings have been acquired. Both of the simulation and the forming test showed that the precision forging of screw propellers could be formed with the isothermal precision forging satisfactorily.

Study of the Precision Forging of an Impeller by Numerical Simulation and Test Forming

2008 ◽  
Vol 141-143 ◽  
pp. 593-598
Author(s):  
Wei Wei Wang ◽  
Fei Han ◽  
Shou Jing Luo
Keyword(s):  
Numerical Simulation ◽  
Flow Line ◽  
Processing Parameters ◽  
Hydraulic Press ◽  
Isothermal Treatment ◽  
Billet Temperature ◽  
Precision Forging ◽  
Die Structure ◽  
Semi Solid ◽  
Forging Die

In the present paper, the precision forging of an impeller was studied by means of numerical simulation and test forming. Based on the structure and dimension of the impeller, the combination structure was used in the forging die to obtain the extrusion deformation. The forming processes were simulated with DEFORM-3D for different billet dimensions and processing parameters. The parameters, which could ensure the forming quality of the impeller, were determined by the calculations and analysis. The die structure and the billet dimensions were determined according to the simulation results, and the forging die was designed and manufactured. The billet with semi-solid microstructure was produced by means of the direct heating-isothermal treatment. The forming was conduced in an YX-315F hydraulic press, and the precision forgings of the impeller were produced successfully. Both of the simulation and the forming test show that the impeller forging can be formed with the combination structure die and the extruding forming stale satisfactorily. The ideal parameters to produce the precision forgings of the impeller are: billet temperature at 625°C, die temperature at 450°C and punch speed at 20mm/s. Under these conditions, forgings of the impeller can be produced with plump blades, smooth outer surface, and good flow line. This can match the requirements of the precision forging of impellers.

Analysis on Temperature Field of Work-Piece during Cross Wedge Rolling

2011 ◽  
Vol 230-232 ◽  
pp. 352-356
Author(s):  
Wen Ke Liu ◽  
Kang Sheng Zhang ◽  
Zheng Huan Hu
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Flow ◽  
Work Piece ◽  
Contact Deformation ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Rigid Plastic ◽  
Finite Element Software ◽  
Deform 3D

Based on the rigid-plastic deformation finite element method and the heat transfer theories, the forming process of cross wedge rolling was simulated with the finite element software DEFORM-3D. The temperature field of the rolled piece during the forming process was analyzed. The results show that the temperature gradient in the outer of the work-piece is sometimes very large and temperature near the contact deformation zone is the lowest while temperature near the center of the rolled-piece keeps relatively stable and even rises slightly. Research results provide a basis for further study on metal flow and accurate shaping of work-piece during cross wedge rolling.

Numerical Simulation of Precision Forming for Blade Rotor Based on DEFORM

2011 ◽  
Vol 130-134 ◽  
pp. 2388-2391
Author(s):  
Fang Liu ◽  
Lu Yun Zhang
Keyword(s):  
Numerical Simulation ◽  
Metal Flow ◽  
Flow Rule ◽  
Stress And Strain ◽  
Deformation Characteristics ◽  
Forming Process ◽  
Plastic Forming ◽  
Deform 3D

In order to study the deformation characteristics of the blade rotor in the precision forming, by means of the plastic forming software DEFORM-3D, the forming process is simulated. It is concluded that (1) the change of the stress and strain in different stages was simulated during the entire forming process. (2) Based on the stress and strain distributions, the analysis of the metal flow rule and the mechanism of the filling mold was proceeded to find that the properties of the blade rotor can be enhanced by means of the precision forming.

Effects of Die Tooth Profile on Forming Helical Tooth Shaft in Cross Wedge Rolling

2013 ◽  
Vol 274 ◽  
pp. 165-169 ◽  
Author(s):  
Hua Jun Yan ◽  
Jin Ping Liu ◽  
Zheng Huan Hu ◽  
Peng Biao Han ◽  
Hao En Mao ◽  
...  
Keyword(s):  
Tooth Profile ◽  
Analysis Software ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Element Analysis ◽  
Rolling Experiment ◽  
Forming Characteristics ◽  
Deform 3D ◽  
Material Saving ◽  
Good Agreement

The study on forming helical tooth shaft processes in cross wedge rolling can contribute to the advantages of material-saving and efficient. Die tooth profile is an important process parameter of cross wedge rolling helical tooth shaft. Three kinds of forming process of die helical teeth were simulated by DEFORM-3D finite element analysis software to analyze three different die helical tooth. According to the tooth forming characteristics, the effects of three kinds of die tooth profile on forming of a polled piece were analyzed. When rolling a polled piece using the die with the same addendum width, it is convenient for die processing and the effect of polled piece forming is better; when using the die with the narrow front and gradually wider rear, the defects of uneven tooth bottom and larger pitch may happen. The rolling experiment was made by using the die with the same width at the tooth bottom. The results are in good agreement with the simulation. Therefore, we should use the die with unchanged addendum width, tooth height and the sidewall proportional increased when designing the die.

Effects of Friction on Precision Forging Process of Blade with a Damper Platform

2007 ◽  
Vol 561-565 ◽  
pp. 831-834 ◽  
Author(s):  
Yu Li Liu ◽  
He Yang ◽  
Tao Gao
Keyword(s):  
High Efficiency ◽  
Metal Flow ◽  
Vibration Characteristic ◽  
Technological Parameters ◽  
Forging Process ◽  
Precision Forging ◽  
Blade Forging ◽  
Deformation Defects ◽  
3D Software ◽  
Deform 3D

A blade with a damper platform, with excellent anti-vibration characteristic and high efficiency, has become one of the most important types of blades being developed in the aeronautical engines. During the precision forging process of this blade, the friction between dies and workpiece has important effects on metal flow, deformation defects, load and energy etc. So researching the effects of friction conditions on the forging process of blade with a damper platform has been a crucial problem urgent to be resolved. In this paper, the precision forging process of titanium alloy blade with a damper platform under different friction conditions has been simulated and analyzed based on the DEFORM-3D software platform. The obtained results reveal the influence laws of friction on temperature field and load-stroke curves, and provide a significant basis for determining technological parameters of the blade forging process.

Process and Properties on the Precision Forming of Spline Cold Rolling

2010 ◽  
Vol 154-155 ◽  
pp. 191-196 ◽  
Author(s):  
Zhi Qi Liu ◽  
Jian Li Song ◽  
Yong Tang Li ◽  
Xu Dong Li ◽  
Ming Fu Wang
Keyword(s):  
Plastic Deformation ◽  
Cold Rolling ◽  
High Efficiency ◽  
Flow Line ◽  
Metal Flow ◽  
Impact Resistance ◽  
Rolling Process ◽  
Plastic Deformation Zone ◽  
Forming Process ◽  
Involute Spline

Cold rolling precision forming process of spline is one of the high-efficiency, precision and non-chip forming advanced manufacturing technologies. It has the characteristics such as high forming efficiency, energy-saving, low material consumption and better forming properties of components. The principle and the force of involute spline cold rolling precision forming process were analyzed. Forming experiments of involute spline cold rolling were carried out, and the microhardness map of the tooth outline was gained. The rule of the metal flow in the deforming area and the forming mechanics of the microstructure were analyzed. The influence of plastic deformation on the forming properties was also conducted. Experimental results showed that dramatic plastic deformation has taken place on the upper surface of the workpiece during the cold rolling process of spline, while the influence on the inner materials were very small. The grains were distributed as a flow line pattern along the tooth profile, and the grains in the plastic deformation zone presented a fine and long fibrous state. The hardness on the section of the tooth outline is regularly distributed. Compared with the spline components obtained from conventional cutting method, the hardness of the spline was greatly increased, therefore, comprehensive mechanical property such as wear resistance and impact resistance were largely improved. Precision measuring and hardness testing of the tooth outline section showed that the components obtained by the experiments were free of defects, and the application requirement can be satisfied.

Flash Design for Automatic Transfer System of Bearing Hub in Hot Forging Process

2006 ◽  
Vol 116-117 ◽  
pp. 120-123
Author(s):  
Sang Kon Lee ◽  
Hyun Sang Byun ◽  
Byung Min Kim ◽  
Dae Cheol Ko ◽  
C.G. Kang
Keyword(s):  
Numerical Analysis ◽  
Metal Flow ◽  
Hot Forging ◽  
Experimental Results ◽  
Transfer System ◽  
Forging Process ◽  
Hot Forging Die ◽  
Forging Die ◽  
Hot Forging Process ◽  
Forging Load

The aim of this study is to design flash geometry of bearing hub to apply the automatic transfer system in hot forging process. The flash geometry is very important in hot forging process because the flash geometry effects on the metal flow, material losses, forging load, die pressure and so on. In this study, the problem of designing the flash geometry is studied with flash thickness and width considering the maximum die pressure to apply an automatic transfer system in hot forging process for bearing hub. The numerical analysis was conducted by means of the commercial S/W DEFORM. On the basis of numerical analysis the flash geometry of hot forging die was redesigned, and experiment was conducted. From the experimental results, it was possible to produce bearing hub with an automatic transfer system without any deterioration of die lifetime.

Numerical Analysis of Rolling Extrusion Process of a Toothed Shaft from Titanium Alloy Ti6Al4V

2014 ◽  
Vol 622-623 ◽  
pp. 1215-1220
Author(s):  
Jarosław Bartnicki ◽  
Janusz Tomczak ◽  
Zbigniew Pater
Keyword(s):  
Titanium Alloy ◽  
Numerical Analysis ◽  
Metal Flow ◽  
Fem Analysis ◽  
Extrusion Process ◽  
Technological Parameters ◽  
Forming Process ◽  
Radial Forces ◽  
Titanium Alloy Ti6al4v ◽  
Deform 3D

This paper presents results of numerical calculations of rolling extrusion process of a toothed shaft made from titanium alloy Ti6Al4V. FEM analysis was conducted applying the software DEFORM 3D for the process chosen technological parameters. The kinematics of metal flow in the area of the formed teeth was analyzed. Distributions of stresses, strains and temperatures during teeth forming were determined. Calculated values of axial and radial forces and moments acting on rotating roll tools allow for designing of tools for experimental verification of the designed forming process.

Optimization Design of Forging Die for Supporting Bar Based on DEFORM-3D

2012 ◽  
Vol 602-604 ◽  
pp. 1869-1873
Author(s):  
Lei Fu ◽  
Li Lin
Keyword(s):  
Contact Stress ◽  
Optimization Design ◽  
Working Life ◽  
Work Piece ◽  
Die Structure ◽  
Die Stress ◽  
Simulation Results ◽  
3D Solid ◽  
Forging Die ◽  
Deform 3D

On the basis of analyzing the process of supporting bar forging conform, the 3D solid geometries modeling of billet and die were constructed by SOLIDWORKS software, the distributions of die stress and contact stress on the process of supporting bar forging conform were analyzed by using DEFORM-3D program. The working life of the die punch was assessed. The die structure was optimized based on the simulation results, and the forging defect of the improved work piece could be well controlled and the die working life was improved to about 10%.

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