Experimental Study of Hot Forming Process by Direct Resistance Heating

2011 ◽  
Vol 704-705 ◽  
pp. 252-260 ◽  
Author(s):  
Zheng Xing Men ◽  
Jie Zhou ◽  
Zhi Min Xu
Keyword(s):  
Experimental Study ◽  
Plastic Deformation ◽  
Hot Forging ◽  
Heating Time ◽  
Resistance Heating ◽  
Forming Process ◽  
Heating Efficiency ◽  
Cylindrical Billet ◽  
Forming Temperature ◽  
Forming Condition

In order to increase heating efficiency and decrease heating time, a new hot-forging method by means of direct resistance heating was investigated in this paper. Based on the approach, the hot upsetting experiments with cylindrical billet of 42CrMo4 were performed. Moreover, the influence of the multi-layer aluminium foils inserted between the billet and the die as a forming condition on heating and forming was researched. The results of the experiments show that prior to forming the billet could be heated quickly to forming temperature in about 10 seconds. During the upsetting process the billet cooling rate was effectively decreased and the forming time was extended in relation to the resistance heating. The insertion of multi-layer aluminium foils not only improved the efficiency of the heating, but also avoided the plastic deformation of the die and the occurrence of cracks on the billet’s surface. Keywords: Resistance heating, Hot forging, upsetting, Aluminium foils Introduction

scholarly journals Application of Direct Resistance Heating in Hot Forging and Analysis of Processing Parameters based on Thermo-electro-mechanical Coupling FEM

2018 ◽  
Vol 37 (6) ◽  
pp. 531-538
Author(s):  
Men Zhengxing ◽  
Wang Menghan ◽  
Ma Yaxin ◽  
Yue Taiwen ◽  
Liu Ruilin
Keyword(s):  
Contact Resistance ◽  
Heating Temperature ◽  
Hot Forging ◽  
Processing Parameters ◽  
Experimental Results ◽  
Transient Temperature ◽  
Resistance Heating ◽  
Forming Process ◽  
Mechanical Coupling ◽  
Forming Temperature

AbstractA series of experiments were designed in order to directly heat the billet of 42CrMo4 to the forming temperature in the dies prior to forming and continue to heat the billet during the forming process. Processing parameters during heating and forming were investigated by experimental method and thermo-electro-mechanical coupling FEM. The experimental results show that prior to forming the billet could be rapidly heated to forming temperature under relatively low initial contact pressure, and the heating temperature was proportional to the square of the current intensity. When the heating current remained constant, the heating temperature could not increase with heating time. During the forming process, the billet cooling rate slowed down and the forming time was extended due to the continuous resistance heating during forming. Finally, an incrementally coupled thermo-electro-mechanical model has been developed to analyze the hot-forging process by direct resistance heating. To obtain the transient temperature field prior to forming, a simple model of contact resistance was used in the thermal-electrical simulation, in which the electrical conductance of the contact resistance was proportional to the heating temperature. Contrasted the experimental results and the simulation results, it was found that they coincided well.

Direct Heating Billet within Die during Hot Forging Process

2013 ◽  
Vol 479-480 ◽  
pp. 25-29 ◽  
Author(s):  
Fang Sung Cheng ◽  
Yu Shun Cheng
Keyword(s):  
Hot Forging ◽  
High Strength ◽  
Heating System ◽  
Heating Time ◽  
Resistance Heating ◽  
Heating Efficiency ◽  
Forging Process ◽  
Direct Heating ◽  
Forging Die ◽  
Hot Forging Process

This paper reports a simple and effective method to increase heating efficiency and decrease heating time that renders direct heating billet within die using resistance heating system during hot forging process. The apparatus employs resistance equipment set into the forging die, and the billet was directly resistance heating by the forging die. Base on the approach, the die as a forming condition on direct heating and forging was also researched. The result of experiments shows that the billet could be heated quickly to 1000°C in about 5 seconds and the high strength material (AISI4140) was successfully formed to the shape of bolt head. With this mechanism, the rapidly heating and isothermal deformation during the hot forging process can be achieved.

The Thickness Thinning Criterion of Vacuum Forming Refrigerator Inner Liner for HIPS

2011 ◽  
Vol 306-307 ◽  
pp. 619-623
Author(s):  
Wen Bin Su ◽  
Tao Li ◽  
Xiang Bing Sun ◽  
Bao Jian Liu
Keyword(s):  
Plastic Deformation ◽  
Deformation Energy ◽  
Forming Process ◽  
Forming Mechanism ◽  
Vacuum Forming ◽  
Forming Condition

In this paper, the regularity of thickness thinning was analyzed from the perspective of controlling the plastic deformation energy during the forming process, then a thickness thinning criterion based on vacuum forming was proposed, and then the forming mechanism of thickness thinning was revealed. Experiment results have shown that the proposed thickness thinning criterion can predict the quality of refrigerator inner liner under new forming condition effectively.

Pengaruh Penggunaan Batu Basalt Lampung dan Batubara dalam Bahan Baku terhadap Karakteristik Klinker

2020 ◽  
Vol 10 (1) ◽  
pp. 49
Author(s):  
Suharto Suharto ◽  
Muhammad Amin ◽  
Muhammad Al Muttaqii ◽  
Syafriadi Syafriadi ◽  
Kiki Nurwanti
Keyword(s):  
Experimental Study ◽  
Raw Materials ◽  
Coal Ash ◽  
Heating Time ◽  
Raw Material ◽  
Silica Sand ◽  
Cement Clinker ◽  
Duration Of Heating

Experimental study on the use of basalt stone originated from Lampung has been conducted to evaluate its potential for a partial substitute of raw material in production of cement clinker. The basalt stone contains minerals of anorthite, augite, and albite phases that are required for clinker formation. In this study, the main raw materials were 80% limestone, 10% silica sand, 9% clay and 1% iron sand. The raw material in these experiments were mixtures 90% or 80% of the main raw material and 10% or 20% of basalt stone. The effect of adding coal to raw materials was also studied to see the possibility of an increase in clinkerization temperature inside the raw material mixture, and at the same time to see the effect of coal ash on clinker composition. Clinker obtained from heating of raw materials at a temperature of 1100oC had LSF of 94.1% and 95.1% (heating time of 1 and 3 hours). If heating is carried out at 1200oC, the clinker had LSF of 97.7% and 98.0% (heating time of 2 and 3 hours, respectively). Depending on the temperature and duration of heating, the clinker mostly had SM in the range of 2.18-2.40% , and AM in the range of 0,78-1.80%. Characterization using XRD showed that the clinker consisted of larnite and gehlenite phases, and dominated by CaO.Batu basalt Lampung telah diuji potensinya sebagai pengganti sebagian bahan baku utama pembuatan klinker semen. Batu basalt tersebut memiliki mineral-mineral dalam fase anorthite, augite, dan albite yang diperlukan pada pembentukan klinker. Pada penelitian ini, bahan baku utama adalah batu kapur 80%, pasir silika 10%, tanah liat 9% dan pasir besi 1%. Campuran bahan baku klinker adalah 90% atau 80% bahan baku utama dan 10% atau 20% batu basalt. Efek penambahan batubara ke dalam bahan baku klinker juga dipelajari untuk melihat kemungkinan kenaikan temperatur klinkerisasi di dalam campuran bahan baku, dan sekaligus untuk melihat efek abu batubara terhadap komposisi klinker. Klinker hasil pemanasan bahan baku pada temperatur 1100oC memiliki LSF 94,1% dan 95,1% (lama pemanasan 1 dan 3 jam). Jika pemanasan dilakukan pada 1200oC, klinker memilik LSF 97,7% dan 98,00% (lama pemanasan 2 dan 3 jam). Tergantung pada temperatur dan lama pemanasan, klinker hasil percobaan ini umumnya memiliki SM 2,18-2,40%, dan AM antara 0,78-1,80%. Karakterisasi dengan XRD menunjukkan bahwa klinker terdiri dari fase larnite dan gehlenite, dan didominasi CaO.

Numerical Simulation and Process Optimization of Automotive Friction Materials in Warm Pressing Forming

2013 ◽  
Vol 788 ◽  
pp. 57-60
Author(s):  
Chun Cao ◽  
Chun Dong Zhu ◽  
Chen Fu
Keyword(s):  
Process Optimization ◽  
Heating Temperature ◽  
Maximum Energy ◽  
Heating Time ◽  
Product Performance ◽  
Forming Process ◽  
Friction Materials ◽  
Forming Technology ◽  
The Relationship ◽  
Temperature Heating

Warm pressing forming technology has been gradually applied to the forming of automotive friction materials. How to ensure product performance to achieve the target at the same time achieve the maximum energy saving is the research focus of this study. In this paper, by using finite element method, the field of automotive friction materials in warm pressing forming was analyzed, reveals the relationship between the temperature field and the heating temperature/heating time. Furthermore, the energy consumption was analyzed and compared it with hot pressing forming process. The results will have significant guiding to the process optimization in warm pressing forming.

Using Reconfigurable Tooling and Surface Heating for Incremental Forming of Composite Aircraft Parts

2003 ◽  
Vol 125 (2) ◽  
pp. 333-343 ◽  
Author(s):  
Daniel F. Walczyk ◽  
Jean F. Hosford ◽  
John M. Papazian
Keyword(s):  
Heating Time ◽  
Mold Surface ◽  
Process Automation ◽  
Forming Process ◽  
The Past ◽  
Air Jets ◽  
Heated Air ◽  
Composite Forming ◽  
Computer Controlled ◽  
Flat Lay

The application of composites in the aircraft industry has increased significantly over the past few decades. With traditional composite laminate shaping, each layer is made to conform to the mold surface by hand before subsequent layers are added. This is a very labor- and time-intensive process. There is a great deal of interest in developing an automated process for forming composite parts with compound curvatures. The proposed composite forming process utilizes a computer-controlled, reconfigurable discrete element mold to incrementally form a compound curvature part shape from a flat lay-up, thereby facilitating process automation. An elastomeric interpolating layer, called an interpolator, is placed on top of the hemispherical forming ends of the die elements to prevent dimpling of the composite lay-up. The process employs vacuum to pull a single diaphragm (top), composite, and interpolator into contact with the mold surface. Through an experimental investigation, this new composites forming process with “active” tooling has been successfully demonstrated. Heating of the composite is accomplished by uncontained, forced convection using a matrix of heated air jets mounted above the composite. However, low-powered conduction is shown to be the best heating method in terms of both composite heating time and minimization of through-thickness temperature. Using vacuum to conform both the composite and the interpolator to the mold, and choosing sufficiently stiff diaphragm and interpolator materials, undimpled and wrinkle-free composite parts have been formed in an incremental fashion.

Application Self-Regulating Heating Cable Curing of Concrete in Winter

2014 ◽  
Vol 638-640 ◽  
pp. 1531-1535 ◽  
Author(s):  
Jin Bao Guo ◽  
Lin Liu ◽  
Qiang Wang
Keyword(s):  
Heat Dissipation ◽  
Heating Temperature ◽  
Heating Time ◽  
Minimum Length ◽  
It Use ◽  
Heating Efficiency ◽  
Cable Length ◽  
Heating Cable ◽  
Curing Methods ◽  
Two Parameters

In order to solve the shortcomings of traditional methods of concrete curing in winter, proposed self-regulating heating cable new concrete curing methods. Several aspects were considered, about the heating cable length and heating time, heating temperature. According to energy conservation, heating and heat dissipation balance, derived formulas of heating cable normal use length and minimum. As conclusions is shown, first, the normal length design can controlled better heating temperature, it use the cable length and heating time, heating temperature two parameters to control the other parameters. Second, it is better heating efficiency, can be the overall warming state quickly. In addition, when the concrete pouring temperature is above 10 °C, it is not need additional heating, and it can choose minimum length design formula.

Effect of process parameters on formability in two-point incremental forming-machining of planar and twisted AA5083 blades

2022 ◽  
pp. 095440542110697
Author(s):  
Hossein Ghorbani-Menghari ◽  
Mehrdad Azadipour ◽  
Mehran Ghasempour-Mouziraji ◽  
Young Hoon Moon ◽  
Ji Hoon Kim
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Dimensional Accuracy ◽  
Numerical Control ◽  
Machining Process ◽  
Curved Surface ◽  
Forming Process ◽  
Forming Temperature ◽  
Feature Based ◽  
Tool Diameter

The deformation machining process (DMP) involves machining and incremental forming of thin structures. It can be applied for manufacturing products such as curved-surface blades without using 5-axis computerised numerical control machines. This work presents the effect of tool diameter and forming temperature on spring-back and dimensional accuracy of a simple fabricated part. The results of the first phase of the study are utilised to design the fabrication process of a curved surface blade. A feature-based algorithm is used to design the tool path for the forming process. The dimensional accuracy of the final product is improved through warm forming, two-point incremental forming, and extension of the bending zone to the outside of the product edges. The results show that DMP can be used to fabricate complex curved-surface workpieces with acceptable dimensional accuracy.

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