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Relevant bibliographies by topics / Forging Process Design

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Academic literature on the topic 'Forging Process Design'

Author: Grafiati

Published: 4 June 2021

Last updated: 1 February 2022

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Journal articles on the topic "Forging Process Design"

1

Wang, Jian Jun, Su Lan Hao, Lu Pan, and Yan Ming Zhang. "The Improvement and Finite Element Analysis of Large Crankshaft Forging Process." Applied Mechanics and Materials 365-366 (August 2013): 561–64. http://dx.doi.org/10.4028/www.scientific.net/amm.365-366.561.

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In view of large load, the shape of large crank forgings and forging process are designed reasonably. Large crank forging process is simulated by numerical simulation software DEFORM-3D to improve the forging process and the dies, including adding upsetting step and related dies. The result shows that improved process and dies can obtain higher quality finish forgings and the load reduces to a rational level, which provides basis for crank forging process and die design.

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Hawryluk, Marek, Zbigniew Gronostajski, Maciej Zwierzchowski, Paweł Jabłoński, Artur Barełkowski, Jakub Krawczyk, Karol Jaśkiewicz, and Marcin Rychlik. "Application of a Prototype Thermoplastic Treatment Line in Order to Design a Thermal Treatment Process of Forgings with the Use of the Heat from the Forging Process." Materials 13, no. 11 (May 27, 2020): 2441. http://dx.doi.org/10.3390/ma13112441.

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The global production of die forgings is an important branch of the motor industry for obvious reasons, resulting from the very good mechanical properties of the forged products. The expectations of the recipients, beside the implementation of the forging process, include also a range of supplementary procedures, such as finishing treatment including shot blasting, thermal treatment, and machining, in order to ensure the proper quality of the provided semi-product or the ready detail for the assembly line. Especially important in the aspect of the operational properties of the products is the thermal treatment of the forgings, which can be implemented in many variants, depending on the expected results. Unfortunately, a treatment of this type, realized separately after the forging process, is very time and energy-consuming; additionally, it significantly raises the production costs due to the increased energy consumption resulting from the necessity of repeated heating of the forgings for such thermal treatment. The article reviews the most frequently applied (separately, after the forging process) thermal treatments for die forgings together with the devices/lines assigned for them, as well as presents an alternative (thermoplastic) method of forging production with the use of the forging heat. The paper also presents a prototype semi-industrial controlled cooling line developed by the authors, which allows the development of the assumed heat treatment of forgings directly after forging with the use of forging heat, together with sample results of conducted tests.

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Chen, Yan, Song Wei Wang, Hong Wu Song, and Shi Hong Zhang. "Forging Process Design and Simulation Optimization of a Complex-Shaped Aluminium Alloy Component." Materials Science Forum 941 (December 2018): 784–89. http://dx.doi.org/10.4028/www.scientific.net/msf.941.784.

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In order to meet the requirements of lightweight and replace steel with the aluminum for a component on the high speed rail, the forging process of a complex-shaped aluminum alloy component was researched and the parameters were optimized with the DEFORM-3D finite element simulation technology. The qualified products were finally obtained instead of the original steel castings by reducing weight of 65%. It is noted that the parts with complicated shape and non-symmetry, metal flow uneven during forging process that lead to incomplete forming, higher forging pressure problems. In this paper, such problems were analyzed couple with numerical simulation method based on a certain forming pressure. Moreover, the model and slot was reasonably designed. In addition, the size of blank was constantly optimized to change the metal flows direction and cavity filling mode. Finally, the forgings with good surface quality and mechanical properties were obtained by production test, and can be used as reference for this kind of forging components.

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Kakimoto, Hideki, Yoichi Takashi, Hideki Takamori, Tatsuya Tanaka, and Yutaka Imaida. "Process Design of Extend Forging Process Using Numerical Simulation Development of Process Design Method for the Finish Forging Process." MATERIALS TRANSACTIONS 50, no. 8 (2009): 1998–2004. http://dx.doi.org/10.2320/matertrans.p-m2009814.

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Tomczak, Janusz, and Arkadiusz Tofil. "Design and technological capabilities of a universal forging mill." Mechanik 90, no. 11 (November 13, 2017): 988–90. http://dx.doi.org/10.17814/mechanik.2017.11.158.

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The paper presents selected results of the research related to the development and verification of a multi-purpose construction of forging mill suitable for the following processes: longitudinal roll forging, cross-wedge rolling, and steel bar cropping. Modern CAD/CAE numerical tools have been used to facilitate the design and analysis of the construction. The designed forging mill is characterized by high versatility due to the possibility of two different kinematic processes of roll forging (longitudinal and transverse) as well as semi-products waste-free cropping. Its technological capabilities are considerably higher as compared to the machines currently used in industry. Verification of adopted construction solutions was made during the commissioning tests. The achieved results have fully confirmed the usefulness of multi-task forging mill for rolling forgings and preforms as well as cropping process.

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Gao, Jian Xin, Pei Feng Zhao, Ke Xing Song, and Qing Wang. "The Numerical Simulation of Conductive Body Forming Process and Mould Design." Materials Science Forum 704-705 (December 2011): 177–82. http://dx.doi.org/10.4028/www.scientific.net/msf.704-705.177.

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T2-copper conductive body is a important part used in high voltage switch, it has poor machining process due to the complex shape. Through Deform numerical simulation, conductive body was formed by open-die forging and closed die forging. In the open-die forging simulation，heat transfer coefficient between blank (880°C) and open-die (200°C) is 11, the surrounding environment temperature is 20°C, friction factor is 0.3. The main open-die forging process parameters is: outer draft angle α=6.5°; inner draft angle β＝10°; bridge width b＝5、8、11mm. punching skin and cylindrical blank. Simulation results show that forging can meet the requirement while properly adjusting mould parameters. The main size of closed-die forging working parts is designed according to the conductive body graph, no draft angle and ring blank of external diameter Φ111mm and inside diameter Φ93mm with the same volume of conductive body. The simulation results shows that forging can be formed using open-die forging, and it is difficult to form product by the process of the closed-die forging for ring blank because of the restriction of solid state metal liquidity, many regions of the filling is not sufficient. Open-die forging and casting blank-closed die forging are both used in actual production. The casting blank-closed die forging is a more reasonable forming process compared with the open-die forging as metal volume of distribution is solved, higher utilization rate of material, more simple process in following work and the like. To make it more suitable for practical production, appropriate adjustments of some parameters was made in the mold design process based on the numerical simulation. Keywords: open-die forging; casting blank–closed die forging; numerical simulation

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Dai, Yan Yan, Shi Qiang Lu, Ke Lu Wang, and Shu Zhe Shang Guan. "Optimization of Pre-Forging of the Aircraft Wheel Hub by FEM." Advanced Materials Research 652-654 (January 2013): 2029–33. http://dx.doi.org/10.4028/www.scientific.net/amr.652-654.2029.

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Optimization and design for shape and size of pre-forging with numerical simulation have some advantages compared with the conventional methods. The optimization object is the pre-forgings of an aircraft wheel hub. A commercially available software DEFORM 3D is used for the finite element method (FEM) simulation of the forging process of the aircraft wheel hub. The pre-forgings with three different shapes and sizes were used for numerical simulation. The effects of shape and size of the pre-forging on mould filling, forging load, effective strain and effective stress were analyzed. Finally, the suitable shape and size of the pre-forging were obtained based on the numerical simulation results.

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Yang, Tung-Sheng, and Jhong -Yuan Li. "Study on forging process and die design of parking sensor shell." MATEC Web of Conferences 185 (2018): 00020. http://dx.doi.org/10.1051/matecconf/201818500020.

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The process of precision forging has been developed recently because of its advantages of giving high production rates and improved strength. For complete filling up, predicting the power requirement and final shape are important features of the forging process. A finite element method is used to investigate the forging force, the final shape and the stress distribution of the parking sensor shell forging. The stress-strain curve of AL-6082 is obtained by the computerized screw universal testing machine. The friction factor between AL-6082 alloy and die material (SKD11) are determined by using ring compression test. Stress-strain curve and fiction factor are then applied to the finite element analysis of the parking sensor shell forging. Maximum forging load, effective stress distribution and shape dimensions are determined of the parking sensor shell forging, using the finite element analysis. Then the parking sensor shells are formed by the forging machine. Finally, the experimental data are compared with the results of the current simulation for the forging force and shape dimensions of the parking sensor shell.

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Liao, Chien-Chou, Chih-Chun Hsu, Jie-Hong Huang, Wen-Chieh Chen, Yiin-Kuen Fuh, Chun-An Liao, and Huan-Yu Chiu. "Deformation mechanism of forging tool for multi-stage forming of deep groove ball bearing." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 233, no. 4 (May 21, 2018): 1182–95. http://dx.doi.org/10.1177/0954405418774596.

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In this study, two design configurations routinely adopted in actual mass production for deep groove ball bearing rings of multi-stage warm forging process are investigated numerically and experimentally. The deformation mechanism, forging defects, microstructures, and compositions analysis are the main focus of this study. For type A design with a stepped configuration, inner and outer rings are automatically pierced and separated in the multi-step forging machine. On the other hand, for the type B geometry, additional step is required by the customized milling machine. For type A design, the main issue encountered during actual forging process is the inadequate material filling at the upper corner radius and folding defects at the transition area of inner wall of forgings. For type B design, the material flow is unsatisfactorily directed and lower outer radius is insufficiently filled. Therefore, variations of forging parameters include billet weight, punch/knock out pin geometry and the effect of lubricating fluid is systematically investigated. In addition, the finite element method has been performed and compared with the actual forging experiments. In summary, the modification of tooling design, dimension variation of billet weight, and the forging temperature difference as impacted by the lubricating fluid, which are identified as the three major factors of the forging integrity and stability of the mass production process. The results are particularly useful for the advanced tooling design and contribute largely to minimize the tool failure and the integrity of the bearing forged.

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KAKIMOTO, Hideki, Yoichi TAKAHASHI, and Hideki TAKAMORI. "Process Design of Extended Forging Process by Numerical Simulation." Journal of the Japan Society for Technology of Plasticity 49, no. 568 (2008): 403–8. http://dx.doi.org/10.9773/sosei.49.403.

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Dissertations / Theses on the topic "Forging Process Design"

1

Mao, Yongning. "Forging Process Design for Risk Reduction." The Ohio State University, 2009. http://rave.ohiolink.edu/etdc/view?acc_num=osu1237565667.

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Ozturk, Huseyin. "Analysis And Design For Aluminum Forging Process." Master's thesis, METU, 2008. http://etd.lib.metu.edu.tr/upload/12610270/index.pdf.

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Aluminum forging products has been increasingly used in automotive and aerospace industry due to their lightness and strength. In this study, aluminum forging processes of a particular industrial part for the two different alloys (Al 7075 and Al 6061) have been analyzed. The forging part, forging process and the required dies have been designed according to the aluminum forging design parameters. The proposed process has been simulated by using the Finite Volume Method. In the simulations, analysis of the part during forging process has been performed
and the required forging force, the temperature distribution and the effective stress distribution in the parts have been obtained. The forging dies were produced in the METU-BILTIR Center CAD/CAM Laboratory. The experimental study has been performed in the METU-BILTIR Center Forging Research and Application Laboratory. The parts were produced without any defects as obtained in the finite volume simulations. The results of the experiment and finite volume simulation are compared and it has been observed good agreement.

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Sarac, Sevgi. "Design And Thermo-mechanical Analysis Of Warm Forging Process And Dies." Master's thesis, METU, 2007. http://etd.lib.metu.edu.tr/upload/12608826/index.pdf.

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Forging temperature is one of the basic considerations in forging processes. In warm forging, the metals are forged at temperatures about the recrystallization temperature and below the traditional hot forging temperature. Warm forging has many advantages when compared to hot and cold forging. Accuracy and surface finish of the parts is improved compared to hot forging while ductility is increased and forming loads are reduced when compared to cold forging. In this study, forging process of a part which is currently produced at the hot forging temperature range and which needs some improvements in accuracy, material usage and energy concepts, is analyzed. The forging process sequence design with a new preform design for the particular part is proposed in warm forging temperature range and the proposed process is simulated using Finite Element Method. In the simulations, coupled thermal mechanical analyses are performed and the dies are modeled as deformable bodies to execute die stress analysis. Experimental study is also carried out in METU-BILTIR Center Forging Research and Application Laboratory and it has been observed that numerical and experimental results are in good agreement. In the study, material wastage is reduced by proposing using of a square cross section billet instead of a circular one, energy saving and better accuracy in part dimensions is achieved by reducing the forging temperature from the hot forging to the warm forging temperature range.

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Vemuri, Koteswara Rao. "A knowledge-based approach to automate geometric design with application to design of blockers in the forging process /." The Ohio State University, 1986. http://rave.ohiolink.edu/etdc/view?acc_num=osu1487323583622657.

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Mahmood, Tariq. "Knowledge-based process planning and design system for the cold forging of steel." Thesis, Imperial College London, 1991. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.264352.

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Ozgen, Arda. "Cutting Strategies For Forging Die Manufacturing On Cnc Milling Machines." Master's thesis, METU, 2008. http://etd.lib.metu.edu.tr/upload/12609433/index.pdf.

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Manufacturing of dies has been presenting greater requirements of geometrical accuracy, dimensional precision and surface quality as well as decrease in costs and manufacturing times. Although proper cutting parameter values are utilized to obtain high geometrical accuracy and surface quality, there may exist geometrical discrepancy between the designed and the manufactured surface profile of the die cavities. In milling process
cutting speed, step over and feed are the main cutting parameters and these parameters affect geometrical accuracy and surface quality of the forging die cavities. In this study, effects of the cutting parameters on geometrical error have been examined on a representative die cavity profile. To remove undesired volume in the die cavities, available cutting strategies are investigated. Feed rate optimization is performed to maintain the constant metal removal rate along the trajectory of the milling cutter during rough cutting process. In the finish cutting process of the die cavities, Design of Experiment Method has been employed to find out the effects of the cutting parameters on the geometrical accuracy of the manufactured cavity profile. Prediction formula is derived to estimate the geometrical error value in terms of the values of the cutting parameters. Validity of the prediction formula has been tested by conducting verification experiments for the representative die geometry and die cavity geometry of a forging part used in industry. Good agreement between the predicted error values and the measured error values has been observed.

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Ozcan, Mehmet Cihat. "Thermo-mechanically Coupled Numerical And Experimental Study On 7075 Aluminum Forging Process And Dies." Master's thesis, METU, 2008. http://etd.lib.metu.edu.tr/upload/12610000/index.pdf.

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Combination of high strength with light weight which is the prominent property of aluminum alloy forgings has led aluminum forgings used in rapidly expanding range of applications. In this study, to produce a particular 7075 aluminum alloy part, the forging process has been designed and analyzed. The forging process sequence has been designed by using Finite Volume Method. Then, the designed process has been analyzed by using Finite Element Method and the stress, strain and temperature distributions within the dies have been determined. Five different initial temperatures of the billet
438, 400, 350, 300 and 250 degree Celsius have been considered in the thermo-mechanically coupled simulations. The initial temperatures of the dies have been taken as 200 degree Celsius for all these analyses. Finite volume analysis and finite element analysis results of the preform and finish part have been compared for the initial billet temperature of 400 oC. Close results have been observed by these analyses. The experimental study has been carried out for the range of the initial billet temperatures of 251&
#8211
442 degree Celsius in METU-BILTIR Center Forging Research and Application Laboratory. It has been observed that the numerical and the experimental results are in good agreement and a successful forging process design has been achieved. For the initial die temperature of 200 degree Celsius, to avoid the plastic deformation of the dies and the incipient melting of the workpiece, 350 degree Celsius is determined to be the appropriate initial billet temperature for the forging of the particular part.

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Deshpande, Mayur Nandkumar. "IMPROVEMENTS IN HOT FORGING PROCESS - USING ALTERNATIVE DIE MATERIALS AND FINITE ELEMENT ANALYSIS FOR WEAR PREDICTION AND DIE DESIGN OPTIMIZATION." The Ohio State University, 2010. http://rave.ohiolink.edu/etdc/view?acc_num=osu1293467038.

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Drbal, Jindřich. "Využití CAM softwaru PowerMILL 2018 při obrábění formy." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2018. http://www.nusl.cz/ntk/nusl-378868.

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The subject of submitted diploma thesis is complete structure of procedures necessary for the designing and subsequent production of forging dies for production of semi-finished connecting rods. The initial part deals with the design of forging die. Following part is consisted of materials used for production of this type of tools. Ensuing is proposal of tooling for machining of the die following with simulation of the milling processes.

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Mawissi, Kwamivi. "Modèles de représentation et de définition d'outillages de forme complexe : application à le génération automatique de processus d'usinage." Cachan, Ecole normale supérieure, 1995. http://www.theses.fr/1995DENS0001.

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Ce mémoire porte sur l'automatisation de la fonction de préparation a la fabrication permettant de passer de la conception des pièces brutes forgées à la définition et la fabrication des outillages. Notre apport se traduit principalement par la construction d'un modèle de représentation d'outillages qui établit le lien entre les différentes fonctions de production, et l'élaboration d'une méthode originale de génération du processus d'usinage des outillages. Nous proposons un modèle de representation d'outillages, permettant la conceptualisation des données de définition d'ordre géométrique et technologique suivant les aspects sémantiques, structurels et topologiques. Du point de vue des deux premiers aspects, la conceptualisation des données nous a permis de définir quatre éléments génériques (entité complexe, macro-entité, primitive et méta-primitive) qui servent de base a la représentation d'outillages. De plus, nous proposons une description formelle des interférences géométriques entre les éléments permettant de représenter à la fois les topologies locales et globales. Notre méthode de génération du processus d'usinage des outillages est basée sur la notion d'état d'usinage qui s'appuie à la fois sur les informations définies dans le modèle de représentation d'outillages et sur des connaissances d'usinage traduisant le savoir-faire des outilleurs. A cet effet, nous présentons une formalisation pertinente des connaissances d'usinage a partir de laquelle sont construits les états. Pour cette construction, nous avons adopte une démarche semi-ascendante de génération d'états d'usinage. La spécification de ces états, ainsi que la définition et l'ordonnancement des séquences d'usinage correspondantes conduisent à l'élaboration d'une gamme d'usinage des outillages. Enfin, nous validons notre approche sur un exemple industriel. La maquette informatique développée permet d'implémenter les taches de génération de gamme et d'unifier l'ensemble des données de représentation d'outillages dans un modèle objet homogène pour une exploitation pertinente et cohérente des liens existant entre ces données

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Books on the topic "Forging Process Design"

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Blazynski, T. Z. Design of Tools for Deformation Processes. Springer, 2011.

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Blazynski, T. Z. Design of Tools for Deformation Processes. Springer, 2011.

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Z, Blazynski T., ed. Design of tools for deformation processes. London: Elsevier Applied Science Publishers, 1986.

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Book chapters on the topic "Forging Process Design"

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Zhang, Pu, Zhenqiang Yao, and Zhengchun Du. "Analysis of Forging Compliance Process and Design of the Forging Simulator." In Intelligent Robotics and Applications, 276–84. Berlin, Heidelberg: Springer Berlin Heidelberg, 2010. http://dx.doi.org/10.1007/978-3-642-16587-0_25.

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Grandhi, Ramana V., and Raghavan Srinivasan. "Concurrent Engineering Tools for Forging Die and Process Design." In Concurrent Engineering: Tools and Technologies for Mechanical System Design, 465–99. Berlin, Heidelberg: Springer Berlin Heidelberg, 1993. http://dx.doi.org/10.1007/978-3-642-78119-3_20.

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Chen, Wen, Xiaoxun Zhang, and Zhenshan Cui. "Numerical Simulations of Open-Die Forging Process for Manipulator Design." In Intelligent Robotics and Applications, 650–58. Berlin, Heidelberg: Springer Berlin Heidelberg, 2008. http://dx.doi.org/10.1007/978-3-540-88518-4_70.

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Courtois, P., B. Fraikin, J. Oudin, and Y. Ravalard. "The Kinematic Element Method in Plane and Axisymmetric Forging Process Design." In Proceedings of the Twenty-Sixth International Machine Tool Design and Research Conference, 459–66. London: Macmillan Education UK, 1986. http://dx.doi.org/10.1007/978-1-349-08114-1_59.

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Hur, Kwan Do, Hyo Young Lee, and Hong Tae Yeo. "Forging Process Design of Al Rotating Arm Holder by FE Analysis." In Advanced Materials Research, 99–102. Stafa: Trans Tech Publications Ltd., 2007. http://dx.doi.org/10.4028/0-87849-463-4.99.

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Evans, R. W., G. S. Clark, and S. G. McKenzie. "Design of a forging process route for a disc in IMI834." In Large Plastic Deformations, 395–403. London: Routledge, 2021. http://dx.doi.org/10.1201/9780203749173-48.

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Chen, Dyi-Cheng, and Wen-Hsuan Ku. "Analysis of Forging Process in 7075 Aluminium Alloy of Innovative Bicycle Stem Using Taguchi Method." In Design, Fabrication and Economy of Metal Structures, 437–42. Berlin, Heidelberg: Springer Berlin Heidelberg, 2013. http://dx.doi.org/10.1007/978-3-642-36691-8_66.

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Diko, F., and M. S. J. Hashmi. "Computer Aided Metal Flow Simulation and Die Design Optimization for Axisymmetric Forging Process." In Proceedings of the Thirtieth International MATADOR Conference, 235–45. London: Macmillan Education UK, 1993. http://dx.doi.org/10.1007/978-1-349-13255-3_31.

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Hootak, Maiwand, Philipp Kuwert, and Bernd-Arno Behrens. "Numerical Process Design for Compound Forging of Powder – Metallurgical and Solid Dissimilar Workpieces." In Advances in Production Research, 324–32. Cham: Springer International Publishing, 2018. http://dx.doi.org/10.1007/978-3-030-03451-1_32.

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Lee, Sang Kon, Hyun Sang Byun, Byung Min Kim, Dae Cheol Ko, and C. G. Kang. "Flash Design for Automatic Transfer System of Bearing Hub in Hot Forging Process." In Solid State Phenomena, 120–23. Stafa: Trans Tech Publications Ltd., 2006. http://dx.doi.org/10.4028/3-908451-26-4.120.

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Conference papers on the topic "Forging Process Design"

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He, Beichang, Youdong Zhou, Ramesh Gambheera, and Shesh K. Srivatsa. "Turbine Disk Forging Process Optimization." In ASME 1999 Design Engineering Technical Conferences. American Society of Mechanical Engineers, 1999. http://dx.doi.org/10.1115/detc99/dac-8604.

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Abstract This paper addresses one of the important aspects of the turbine disk forging process — the design of die geometry to achieve near-net-shape forging. The problem is formulated as a parametric geometry and high-fidelity analysis based optimization problem. The forging weight is minimized within prescribed processing windows and forging rules including bounds on strain, temperature, strain rate, press capacity, dwell time, sonic coverage, fillet radius, draft angles, etc. A fully automated analysis and optimization system that works in a heterogeneous and networked computing environment is built on the top of three commercial software packages: DEFORM for simulating metal forming process, Unigraphics for defining and manipulating geometry, and iSIGHT for software integration and optimization. The system is applied to the optimization of turbine disks.

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Grandhi, R. V., H. Cheng, and S. S. Kumar. "Optimal Design of Forging Processes With Deformation and Temperature Constraints." In ASME 1993 Design Technical Conferences. American Society of Mechanical Engineers, 1993. http://dx.doi.org/10.1115/detc1993-0433.

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Abstract This paper presents a systematic methodology for the design of process parameters for nonisothermal forgings. The finite element approach is used for deformation and thermal analyses, and an optimal control strategy is used for the process parameter design. A state-space model is developed for representing the coupled deformation and thermal behavior using rigid viscoplastic formulation. Design constraints on strain-rates and temperature variation are imposed for achieving the desired forging conditions. The linear quadratic regulator (LQR) theory for finite time control is used in designing the ram velocity and initial die temperature. The approach is demonstrated on an axisymmetric disc forging and a plane strain channel section forging, under nonisothermal conditions.

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Ho, Chengter, and Jerri Mathew. "Case-Based Reasoning System for Forging Process Design." In 2008 3rd International Conference on Innovative Computing Information and Control. IEEE, 2008. http://dx.doi.org/10.1109/icicic.2008.189.

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Yoshida, Hiroaki, Takeshi Hatta, Tomohisa Hironaka, Sachihiro Isogawa, and Hideaki Sekiguchi. "Process Modelling of IN718 for Free Forging." In MATERIALS PROCESSING AND DESIGN; Modeling, Simulation and Applications; NUMIFORM '07; Proceedings of the 9th International Conference on Numerical Methods in Industrial Forming Processes. AIP, 2007. http://dx.doi.org/10.1063/1.2740939.

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Grandhi, Ramana V., Sesha C. Modukuru, and James C. Malas. "Integrated Strength and Manufacturing Process Design Using a Shape Optimization Approach." In ASME 1990 Design Technical Conferences. American Society of Mechanical Engineers, 1990. http://dx.doi.org/10.1115/detc1990-0078.

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Abstract This paper considers a simultaneous design of product and manufacturing process. The product requirements include strength properties, whereas the manufacturing process goals include cost, quality, and microstructure to produce defect-free parts on a repeatable basis. The concept is demonstrated by designing a turbine disk manufactured using a forging process. A simplified analysis is used in forging process simulation. Formulation of the integrated design problem is emphasized.

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Esche, Sven K., Ismail Fidan, Constantin Chassapis, and Souran Manoochehri. "Knowledge-Based Part and Process Design for Metal Forging." In International Congress & Exposition. 400 Commonwealth Drive, Warrendale, PA, United States: SAE International, 1999. http://dx.doi.org/10.4271/1999-01-0054.

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Qingping, Zhang, Cui Huanyong, and Wang Yuzeng. "Process Design for Cold Precision Forging of Bevel Gear." In 2010 International Conference on Digital Manufacturing and Automation (ICDMA). IEEE, 2010. http://dx.doi.org/10.1109/icdma.2010.193.

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Howson, T. E., and H. E. Delgado. "Utilization of Computer Modeling in Superalloy Forging Process Design." In Superalloys. TMS, 1988. http://dx.doi.org/10.7449/1988/superalloys_1988_515_524.

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Hsiang, Su-Hai, Yi-Cheng Hong, Huey-Lin Ho, and Shiuh-Kuang Yang. "Study on the Formability of Magnesium Alloy Parts Under Hot Forging Process." In ASME 2012 11th Biennial Conference on Engineering Systems Design and Analysis. American Society of Mechanical Engineers, 2012. http://dx.doi.org/10.1115/esda2012-82021.

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Abstract:

This study investigates the formability of AZ31 and AZ61 magnesium alloy for bicycle parts under hot forging process. Firstly, finite element software DEFORM is applied to simulate the deformation behaviors of magnesium alloys bicycle parts under different process parameters. The process parameters considered in the simulation are materials heating temperatures, lubricants and punch speeds. Changes in process parameters, the forging loads and the completeness of filling of material in die cavity are discussed. The optimal forging condition can be obtained from evaluation of the completeness of filling of material in die cavity, forging load and distribution of stress and strain. The experimental conditions are set according to the optimal simulation results. Hot forging experiments are carried out under the condition of heating range from 240°C to 350°C, different kind of lubricants, constant punch speeds 0.9mm/s to study the formability of magnesium alloy for bicycle parts. The experimental results are compare with the DEFORM simulation results. The obtained forging loads and completeness of filling are in good agreement with the simulation results. The validity of the simulation model established in this study can be confirmed. Finally, from the measured result of hardness and metallographic observation of forged part, the influence of forging temperatures on the strength and microstructures of magnesium alloy for bicycle parts under forging process can be evaluated.

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Du, Shiwen, Yongtang Li, and Jianjun Song. "Optimization of Forging Process Parameters and Anvil Design for Railway Axle During High-Speed Forging." In ASME 2015 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2015. http://dx.doi.org/10.1115/imece2015-50695.

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Forging is an effective method for railway axle in order to ensure the inner quality, good microstructure and properties. Based on the disadvantage of current processing techniques for railway axle forging such as large machining allowance, low dimension accuracy, materials and energy consumption, a new precision high-speed forging forming process is proposed. The whole forging process of axle is divided into three steps, including chamfering, rounding and forming. Forming qualities of railway axle mainly depend on anvil structure and operational parameters during high-speed forging. Simulation model is established using finite element method by DEFORM. Focusing on the forging stage of the railway axles, the influences of anvil design have been numerically analyzed. By analyzing the stress-strain distribution and the forming precision with different anvil structures (flat anvil and arc anvil), a new arc anvil for axle forging is proposed. Arc anvil which we put forward is better than flat anvil both forming quality and properties. As for anvil edge shape design, it is effective to select a Per-form zone to obtain high strain at the center. Structure and main parameters are designed. Effect of anvil relative length, transition radius between Per-form zone and relative length, arc radius of arc anvil on forming quality is analyzed in term of surface defects and inner stress-strain distribution. While the radius of arc is 150mm and the central angle of the arc is 90°, the equivalent strain is greater which will be benefit for inner defects cogging. Transition radius between Per-form zone and relative length is 50mm, concave defects on the surface of forging is the smaller. With the increase of relative length, forging force increases. Taking the productivity and inner strain distribution into account, relative length is 240mm. The independent influence of each chosen major operational parameter, i.e, the rotation angle, the feed and the reduction on internal quality and dimensional precision, has been studied. Suitable operational parameters for ensuring internal quality and dimensional precision have been specified. As a result, the optimum combination of rotational angle and relative feed is clarified. Compared with stress-strain distribution and inner strain distribution under different reduction, 20% is taken to ensure better strain status and efficiency, rotation angle is 90°during chamfering. While the relative feed is 0.6, rotation angle is 45° during rounding, rounding precision will be higher. Ellipticity will be best and variance of radius will be small. Experiment research is performed in 10MN high-speed hydraulic press. Compared with the forming size precision, the experimental results verified the feasibility of the structure of arc anvil and the operational parameters.

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