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Journal articles on the topic 'Forging Process Design'

Author: Grafiati

Published: 4 June 2021

Last updated: 1 February 2022

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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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2

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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3

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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4

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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5

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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6

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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7

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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8

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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9

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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10

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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11

KAKIMOTO, Hideki, Takefumi ARIKAWA, Yoichi TAKAHASHI, Tatsuya TANAKA, and Yutaka IMAIDA. "Process Design of Extend Forging Process by Numerical Simulation." Journal of the Japan Society for Technology of Plasticity 50, no. 579 (2009): 343–48. http://dx.doi.org/10.9773/sosei.50.343.

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12

UENO, Kanji, Jun TAZAWA, Koichi ONOYAMA, Iwao SAITO, Shinichiro FUJIKAWA, and Ken-ichiro MORI. "Design of Forging Process for Transmission Gear." Journal of the Japan Society for Technology of Plasticity 52, no. 608 (2011): 1012–16. http://dx.doi.org/10.9773/sosei.52.1012.

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13

Repalle, Jalaja, and Ramana V. Grandhi. "Design of Forging Process Variables under Uncertainties." Journal of Materials Engineering and Performance 14, no. 1 (February 1, 2005): 123–31. http://dx.doi.org/10.1361/10599490522248.

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14

Ozturk, Murat, Sinem Kocaoglan, and Fazil O. Sonmez. "Concurrent design and process optimization of forging." Computers & Structures 167 (April 2016): 24–36. http://dx.doi.org/10.1016/j.compstruc.2016.01.016.

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15

Mancini, Silvia, Luigi Langellotto, Giovanni Zangari, Riccardo Maccaglia, and Andrea Di Schino. "Optimization of Open Die Ironing Process through Artificial Neural Network for Rapid Process Simulation." Metals 10, no. 10 (October 21, 2020): 1397. http://dx.doi.org/10.3390/met10101397.

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The open die forging sequence design and optimization are usually performed by simulating many different configurations corresponding to different forging strategies. Finite element analysis (FEM) is a tool able to simulate the open die forging process. However, FEM is relatively slow and therefore it is not suitable for the rapid design of online forging processes. A new approach is proposed in this work in order to describe the plastic strain at the core of the piece. FEM takes into account the plastic deformation at the core of the forged pieces. At the first stage, a thermomechanical FEM model was implemented in the MSC.Marc commercial code in order to simulate the open die forging process. Starting from the results obtained through FEM simulations, a set of equations describing the plastic strain at the core of the piece have been identified depending on forging parameters (such as length of the contact surface between tools and ingot, tool’s connection radius, and reduction of the piece height after the forging pass). An Artificial Neural Network (ANN) was trained and tested in order to correlate the equation coefficients with the forging to obtain the behavior of plastic strain at the core of the piece.

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16

Huang, Xi Na, Zhi Ping Zhong, Wei Wang, Feng Jiao Li, De Hua Qiu, and Chong Peng. "A Review of Liquid Forging Process." Advanced Materials Research 690-693 (May 2013): 2275–79. http://dx.doi.org/10.4028/www.scientific.net/amr.690-693.2275.

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Liquid forging is a new technology of plastic forming. It is a kind of bulk forming process with liquid metal with high-quality and efficiency and it has the characteristics of both die casting and forging. This paper will discuss the liquid forging process, die design, simulation and optimization of liquid forging [1].

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17

Gontarz, Andrzej, Krzysztof Drozdowski, Anna Dziubinska, and Grzegorz Winiarski. "A study of a new screw press forging process for producing aircraft drop forgings made of magnesium alloy AZ61A." Aircraft Engineering and Aerospace Technology 90, no. 3 (April 9, 2018): 559–65. http://dx.doi.org/10.1108/aeat-11-2016-0238.

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Purpose The aim of this study is to develop a die forging process for producing aircraft components made of magnesium alloy AZ61A using a screw press. Design/methodology/approach The proposed forging technique has been developed based on the results of a numerical and experimental research. The required forging temperature has been determined by upsetting cylindrical specimens on a screw press to examine both plasticity of the alloy and the quality of its microstructure. The next stage involved performing numerical simulations of the designed forging processes for producing forgings of a door handle and a bracket, both made of magnesium alloy AZ61A. The finite element method based on simulation programme, Deform 3D has been used for numerical modelling. The numerical results revealed that the forgings are free from material overheating and shape defects. In addition to this, the results have also helped determine the regions that are the most prone to cracking. The final stage of the research involved performing forging tests on a screw press under industrial conditions. The forgings of door handles and brackets were made, and then these were tested for their mechanical and structural properties. The results served as a basis for assessing both the viability of the designed technique and the quality of the produced parts. Findings The experimental results demonstrate that aircraft components made of magnesium alloy AZ61A can be produced by die forging on screw presses. The results have been used to determine the fundamental parameters of the process such as the optimum forging temperature, the method of tool heating, the way of cooling parts after the forging process, and the method of thermal treatment. The results of the mechanical and structural tests confirm that the products meet the required quality standards. Practical implications The developed forging technique for alloy AZ61A has been implemented by the forging plant ZOP Co. Ltd in Swidnik (Poland), which specializes in the manufacturing of aircraft components made of non-ferrous metal alloys. Originality/value Currently, the global tendency is to forge magnesium alloys (including alloy AZ61A) on free hydraulic presses using expensive die-heating systems. For this reason, the production efficiency of such forging processes is low, while the manufacturing costs are high. The proposed forging technique for alloy AZ61A is an innovative method for producing forgings using relatively fast and efficient machines (screw presses). The proposed forging method can be implemented by forging plants equipped with standard stocks of tools, which increases the range of potential manufacturers of magnesium alloy products. In addition, this technology is highly efficient and ensures reduced manufacturing costs.

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18

Chung, J. S., and S. M. Hwang. "Process Optimal Design in Forging by Genetic Algorithm." Journal of Manufacturing Science and Engineering 124, no. 2 (April 29, 2002): 397–408. http://dx.doi.org/10.1115/1.1406954.

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A genetic algorithm based approach is presented for process optimal design in forging. In this approach, the optimal design problem is formulated on the basis of the integrated thermo-mechanical finite element process model so as to cover diverse design variables and objective functions, and a genetic algorithm is adopted for conducting design iteration for optimization. The process model, the formulation for process optimal design, and the genetic algorithm are described in detail. The approach is applied to several selected process design problems in cold and hot forging.

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19

Chen, Dyi Cheng, Wen Jong Chen, Tai Lin Hong, Sheng Han Chen, Yi Xiang Lin, and Ming Jer Tsai. "Finite Element Analysis and Mold Design of Forging Process of Highway Bicycle Pedal." Materials Science Forum 773-774 (November 2013): 63–69. http://dx.doi.org/10.4028/www.scientific.net/msf.773-774.63.

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Forging is a simple and low-cost mass production process. Metallic materials can be processed using plastic deformation. This research analyzes an innovative forging mold design for the highway bicycle pedal. A series of simulation analyses in which the variables depend on various temperatures of forging billet and mold, friction factors, and forging speed show effective stress, effective strain, and die radial load distribution for a forging process and mold design of a highway bicycle pedal. Finally, we identify the results of simulation analyses with the design of an experimental forging mold to lower deformation behavior of a highway bicycle pedal. The analysis results provide highway bicycle pedal forming mold references to identify whether it is suitable with the finite element results for high-strength mold design.

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20

Kang, Jong Hun, Hyun Jun Kim, and Hyoung Woo Lee. "Forging process design of cup shaped large forging using finite element method." Journal of the Korean Society of Marine Engineering 39, no. 7 (September 30, 2015): 729–34. http://dx.doi.org/10.5916/jkosme.2015.39.7.729.

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21

Zhao, Xin Hai, Jian Chang Bai, and Guo Qun Zhao. "Application of Ant Colony Algorithm in Optimal Preform Design of Forging Process." Advanced Materials Research 1096 (April 2015): 292–96. http://dx.doi.org/10.4028/www.scientific.net/amr.1096.292.

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For the forging with complex shape, the preform design is a difficult problem in the process and die design. It has an enormous influence on the quality of the forging. In this paper, combining with the FEM, the Ant Colony Algorithm was used for the preform optimization design. The general Ant Colony Algorithm was improved to fit for the multivariate continuous function optimization. The preform die shape was represented by B-spline and the coordinates of the control point of the B-spline were taken as the optimization design variables. The optimization program was developed. Finally, aimed to decrease the material cost of the forging, the preform optimization of a typical H-section forging was obtained using the self-developed program. The optimization results show that the improved Ant Colony Algorithm is suitable for the preform optimization design of forging.

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22

Chen, Xue Wen, Dong Won Jung, and Ai Xue Sun. "Hot Forging Process Design Optimization Based on Approximate Model and FEM Simulation." Materials Science Forum 575-578 (April 2008): 334–39. http://dx.doi.org/10.4028/www.scientific.net/msf.575-578.334.

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Technology and die design are very important in the development of forging products due to its great influence on the quality, cost and manufacturing efficiency of the final products as well as the life of the forging die. In the environment of the severe competition, how to improve the quality of forging technology and die design, to reduce the product cost and ultimately to enhance competitiveness of the forging factory are the problems that forging technology and die designer have to solve. In order to improve the quality of forging technology and die design, a design optimization method based on approximate model (response surface model) and FEM technique for hot forging process is proposed in this paper. During design optimization process, finite element analysis is incorporated to calculate the objective function and check the design alternatives. Design of experiment (DOE) method is used to collect sample points and calculate the polynomial coefficients of response surface model, and approximate model is used to calculate the optimum search direction. Finally, a case study is conducted for a gear workpiece hot forging process. The objective function is the degree of uniformity of equivalent-strain, which can be defined as mean square deviation of the equivalent-strain in each element and the average equivalent-strain of all elements, and the design parameters are the initial H0/D0 ratio of billet and the key dimensions of the die. Then the design optimization mathematical model is established. The result shows that the objective function value is dropped from 0.7914 and converges at 0.4843 within 17 iterations, the optimal design parameters are obtained.

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23

Kingsly Jeba Singh, D., and C. Jebaraj. "Feature-based design for process planning of the forging process." International Journal of Production Research 46, no. 3 (November 19, 2007): 675–701. http://dx.doi.org/10.1080/00207540600818310.

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24

Chen, Dyi Cheng, Jiun Ru Shiu, and Jheng Guan Lin. "Optimization Analysis of A7075 Bicycle Stem Forging Process." Key Engineering Materials 554-557 (June 2013): 227–33. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.227.

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This research analyzes an innovative forging mold design for the various bicycle stem. The paper used the rigid-plastic finite element analysis software and structural analysis to investigate the plastic deformation behavior of aluminum alloy A7075 workpiece for forging process. Under various forging conditions, it analyses the effective strain, the effective stress, the temperature changing, surface pressure, mold radius load distribution, stress analysis of billet and mold. Moreover the paper used the Taguchi method combine the algorithm method of artificial neural network to find out the best design parameters. The paper hoped to offer some tolerance um precision forging manufacture knowledge for industry.

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25

Kostalova, Miroslava, and Maria Kapustova. "Optimization of the Raw Part Shape for the “Fork” Production by Computer Simulation." Applied Mechanics and Materials 152-154 (January 2012): 1675–78. http://dx.doi.org/10.4028/www.scientific.net/amm.152-154.1675.

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The article showed procedure of forging technological flow design modification of real component “fork”, with using of computer simulation. By using of the primary technological process at production was produced failure forgings, checking simulation showed incorrect material flow in filling of die cavity, and therefore it was needed to raw part design modifications. These modifications were suggested on base results obtained from simulation, the results were abolition of defects, resolution of problem and correctness verification of final forging technological flow.

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26

Kakimoto, Hideki, Takashi Choda, Youichi Takahashi, Kazuo Fujita, Hiroshi Takahara, and Hiroyuki Mori. "Process Design of RR Forging Using Numerical Simulation." Journal of the Japan Society for Technology of Plasticity 47, no. 548 (2006): 829–34. http://dx.doi.org/10.9773/sosei.47.829.

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27

Choda, Takashi. "Technology for process design of titanium alloy forging." Journal of Japan Institute of Light Metals 65, no. 9 (2015): 460–65. http://dx.doi.org/10.2464/jilm.65.460.

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28

Esche, S. K., C. Chassapis, and S. Manoochehri. "Concurrent Product and Process Design in Hot Forging." Concurrent Engineering 9, no. 1 (March 1, 2001): 48–54. http://dx.doi.org/10.1177/106329301772625420.

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Esche, S. K., C. Chassapis, and S. Manoochehri. "Concurrent Product and Process Design in Hot Forging." Concurrent Engineering 9, no. 1 (March 2001): 48–54. http://dx.doi.org/10.1177/1063293x0100900105.

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30

Esche, S. K., C. Chassapis, and S. Manoochehri. "Concurrent Product and Process Design in Hot Forging." Concurrent Engineering: Research and Applications 9, no. 1 (March 1, 2001): 48–54. http://dx.doi.org/10.1106/p14w-7dlm-44pe-phnj.

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31

Tjøtta, Stig, and Odd Heimlund. "Finite-element simulations in cold-forging process design." Journal of Materials Processing Technology 36, no. 1 (December 1992): 79–96. http://dx.doi.org/10.1016/0924-0136(92)90240-s.

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32

Duggirala, Ravikiran, and Aly Badawy. "Finite element method approach to forging process design." Journal of Materials Shaping Technology 6, no. 2 (June 1988): 81–89. http://dx.doi.org/10.1007/bf02834823.

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33

Inagaki, Yoshiya. "Application of numerical simulation to forging process design." Journal of Japan Institute of Light Metals 70, no. 11 (November 15, 2020): 536–44. http://dx.doi.org/10.2464/jilm.70.536.

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34

Hawryluk, Marek, Marcin Rychlik, Mateusz Więcław, and Paweł Jabłoński. "Analysis of the Industrial Process of Producing a Hub Forging Used in Motorcar Power Transmission Systems—A Case Study." Journal of Manufacturing and Materials Processing 5, no. 2 (April 9, 2021): 32. http://dx.doi.org/10.3390/jmmp5020032.

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The article refers to an analysis of the multi-operation process of manufacturing a hub type forging used to transmit power in motorcar gear boxes, by way of die forging on a crank press. The investigations were performed in order to improve the currently realized production technology, mainly with the use of numerical simulations. Through the determination of the key parameters/quantities during forging, which are difficult to determine directly during the industrial process, an in-depth and complex analysis was performed by way of FE (Finite Element) modelling. A thermomechanical model of producing a hub forging with deformable tools was developed with the use of the Qform 9.0.9 software. For the elaboration and construction of the forging tool CAD (Computer Aided Design) models, the Catia V5R20 program was applied. The results of the performed numerical modelling made it possible to determine the material flow and the properness of the filling of impressions, as well as the temperature field distributions and plastic deformations in the forging; it was also possible to detect the forging defects often observed in the industrial process. On this basis, the changes in the process were determined, which enabled an improvement of the presently realized technology and the obtaining of proper forgings, both in respect of quality and dimensions and shape.

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35

Tofil, Arkadiusz, Janusz Tomczak, and Tomasz Bulzak. "Comparative Analysis of Forging Rolling and Cross-Wedge Rolling of Forgings from Titanium Alloy Ti6Al4V." Key Engineering Materials 687 (April 2016): 141–48. http://dx.doi.org/10.4028/www.scientific.net/kem.687.141.

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Theoretical-experimental results of forging rolling and cross-wedge rolling of stepped shafts forgings from titanium alloy Ti6Al4V are presented in this paper. Theoretical assumptions were based on the results of numerical simulations conducted by means of finite element method with the application of software Simufact Forming. During numerical simulations optimal parameters of the rolling processes were determined in view to possibility of obtaining forgings of assumed quality and stable process course. Experimental verification was conducted in universal forging rolling mill of own design, which allows for realization of such processes as splitting without waste, forging rolling and cross as well as cross-wedge rolling processes. During conducted research influence of the way of rolling on the obtained parts quality and the process force parameters were determined. Complex analysis of the chosen rolling parameters impact on the rolling process course and quality of finished products was made. Conducted research showed that it is possible to roll axi-symmetrical forgings of stepped shafts both in transverse and longitudinal arrangement. However, forgings rolled crosswise are characterized by larger precision than in comparison with semi-finished products in longitudinal arrangement.

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36

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." Solid State Phenomena 116-117 (October 2006): 120–23. http://dx.doi.org/10.4028/www.scientific.net/ssp.116-117.120.

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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.

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Tolkushkin, A. O., Sergey N. Lezhnev, and Abdrakhman B. Naizabekov. "Development and Research of the Billet Forging Technology in the Newly Designed Step-Wedge Dies." Materials Science Forum 946 (February 2019): 750–54. http://dx.doi.org/10.4028/www.scientific.net/msf.946.750.

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One of the main ways to improve product quality, obtained by forging, is implementing shear and alternating deformation (severe plastic deformation) during deformation process, which allows manufacturing products with required mechanical properties and less forging reduction. In practice, it is possible to implement shear and alternating deformation by improving the design of the ingots or the billets, forging tools, heating modes and forging method. In this paper newly designed forging die, which allows implementation of shear and alternating deformation without sufficient changes of the billet sizes, is proposed. By the research results of the new forging technology influence in the proposed tools on the microstructure evolution, it was found, that the use of the newly designed step-wedge dies has more potential for manufacturing high-quality forgings with required level of mechanical properties.

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Henke, Thomas, Markus Bambach, and Gerhard Hirt. "Die and Process Design for Hot Forging of a Gear Wheel – A Case Study." Key Engineering Materials 554-557 (June 2013): 307–16. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.307.

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Gearing components are an example for widely used machining parts in engines. Nowadays the development and optimization of materials and process chains are driven towards a concurrent improvement of final product properties and production efficiency. Excellent mechanical properties needed for gearing components e.g. high load capacity and high fatigue resistance depend on a fine homogeneous microstructure in the final product. Efficiency in gear manufacturing can be optimized by increasing the temperature during processing, which allows for lower forging loads and lower die stresses, thus improving die life in terms of mechanical fatigue. Additionally, increasing the temperature during case hardening reduces the process duration significantly. Hence process efficiency also increases. To meet the need of a fine homogenous microstructure, dynamic recrystallization has to be initiated during hot forging and grain growth has to be avoided during dwell times and case hardening. This grain size control can be achieved by applying micro-alloying concepts. Recently, an Nb-Ti-based alloying concept for case hardening steels was introduced, which increases fine grain stability and therefore potentially allows for higher forging and case hardening temperatures, leading to improved process efficiency [1]. In this paper a 25MoCr4-Nb-Ti steel grade is characterized in terms of flow resistance and microstructure evolution by hot compression tests and annealing experiments. The processing limits of this material in terms of abnormal grain growth are determined and a JMAK-based microstructure model considering these limits is presented and implemented in the FE-Software DEFORM 3dTM. The model is used in a case study to design a laboratory scale forging process for lowest possible die stresses and finest possible grain sizes. Experimentally measured grain sizes and forging loads from forgings at the laboratory scale are used to evaluate the process design. It is shown that considering microstructure evolution in process design is absolutely necessary to jointly optimize for process efficiency and final properties. The application of the Nb-Ti-based micro-alloying concepts allows for lower die stresses and thus seems to reduce mechanical fatigue of the dies compared to conventional case-hardening steels. [1] S. Konovalov et. al.: Testcase gearing component. In: G. J. Schmitz, U. Prahl (Ed.): Integrative Computational Materials Engineering, Wiley-VCH Verlag GmbH & Co. KGaA, 2012, ISBN 978-3-527-33081-2

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Smolik, Jerzy. "Hard Protective Layers on Forging Dies—Development and Applications." Coatings 11, no. 4 (March 24, 2021): 376. http://dx.doi.org/10.3390/coatings11040376.

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The article presents a summary of many years of activities in the area of increasing the durability of forging dies. The results of comprehensive research work on the analysis of the destructive mechanisms of forging dies and the possibility of increasing their durability with the use of modern surface engineering methods are presented. Great possibilities in terms of shaping operational properties of forging dies by producing hybrid layers of the “Nitrided Layer + PVD Coating” (NL + PVD coating) type were confirmed. An analysis of changes in forging dies durability under various operating conditions was performed, i.e., forging—die—forging press—pressures. It has been shown that the variety of parameters of the forging process, including forgings’ geometry and weight, materials, precision, pressures applied, and, what is very important, quality of machines, makes it very difficult to compare the effectiveness of various PVD coating solutions in the process of increasing the durability of forging dies. Hybrid layers of the “NL + PVD coating” type create great possibilities in shaping the operational properties of tools and machine elements. However, in each application a precise diagnosis of the wear mechanism and the design of an individual PVD coating material solution is required.

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Li, Ru Xiong, and Song Hua Jiao. "Roll Forging Technology and 3D Finite Element Simulation of Automobile Front Axle." Applied Mechanics and Materials 178-181 (May 2012): 2845–49. http://dx.doi.org/10.4028/www.scientific.net/amm.178-181.2845.

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According to the characters, technological condition and requirements of automotive front axle forging, the advantage of the roll forging and integral die forging complex process for automobile front axle were explained, including the determination of roll- forging parts chart, selection of billet dimension, decision of roll- forging steps, special roller- shaped design of typical section, and the front sliding parameter is calculated, its effect to length of forging parts gets analyzed. In this paper, taking NHR front axle as an instance, both the process of exact roll- forging billet and die design are studied, as the result, roll- forging die、 performing roll- forging die and final roll-forging die are design respectively. The process for roll forging was simulated by the three dimensional finite element analyses under isothermal condition, and metal flow procedure and force time curve were obtained. The connection among metal flow law and die cavity design and forming load were also analyzed. To verify the reliability of the simulation, the results for profile was compared with the tested forging part, showing that metal flow law of both are coincident and FE simulation of roll forging is accurate. Practice testify that FE simulation of roll forging for front axle can reduce the time of process design and procedure debugging and be helpful to response the market demand.

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Chen, Chang Cheng, and Yi Xuan Qiu. "Experimental Study on Forging Process of Micro Stepped Gear." Key Engineering Materials 626 (August 2014): 541–47. http://dx.doi.org/10.4028/www.scientific.net/kem.626.541.

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This paper proposes an integrated computer-aided design and computer-aided manufacturing procedure to produce the forging die for experiment, and the forging formability of micro stepped gear was explored. In the forging process, this paper proposes a novel hybrid forging method with a single die set which would execute two forging stages including the first stage of Upsetting and the second stage of Clamping type Gear forging. In the case study, the materials were fully filled into tooth cavity of small gear of module 0.12mm. On the other hand, the estimated unfilled rate of bigger gear is less 8 to 12%, showing this method is exactly feasible.

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Li, Rong Chang, and Ai Xia He. "Large Forging Expert System of Diagnosis." Applied Mechanics and Materials 203 (October 2012): 321–24. http://dx.doi.org/10.4028/www.scientific.net/amm.203.321.

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The diagnosis of forging process for large problems, the use of advanced expert system for diagnosis of large forging process, forging process design of a large diagnostic expert system structure is discussed in detail the working principle and function of each module, and to the knowledge representation and reasoning mechanism of the development of key technologies such as policy, practice shows that the expert system can solve large-scale forging process design and diagnosis of problems in the field, in large forging process improvement theory and techniques to improve the forging process with large modules scientific, intelligent with significance.

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Li, Rong Chang, and Ai Xia He. "Large Forging Expert System of Diagnosis." Applied Mechanics and Materials 65 (June 2011): 621–24. http://dx.doi.org/10.4028/www.scientific.net/amm.65.621.

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The diagnosis of forging process for large problems, the use of advanced expert system for diagnosis of large forging process, forging process design of a large diagnostic expert system structure is discussed in detail the working principle and function of each module, and to the knowledge representation and reasoning mechanism of the development of key technologies such as policy, practice shows that the expert system can solve large-scale forging process design and diagnosis of problems in the field, in large forging process improvement theory and techniques to improve the forging process with large modules scientific, intelligent with significance.

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Cheng, Yu Feng, Xiao Guang Yang, Qi Lu, Chao Voon Samuel Lim, and Ai Jun Huang. "Sensitivity Analysis of Process Parameters for Developing an Improved Open Die Forging Process." Key Engineering Materials 622-623 (September 2014): 231–38. http://dx.doi.org/10.4028/www.scientific.net/kem.622-623.231.

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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;

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Yu, Cheng Hsien, and Jinn Jong Sheu. "Cold Forging Die Design and Process Simulation of a Disk with Inner Ring Gear." Key Engineering Materials 626 (August 2014): 211–16. http://dx.doi.org/10.4028/www.scientific.net/kem.626.211.

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Cold forging die design and process simulation were studied in this paper for a disk with center boss and outer ring gear. The complexity of part geometry results in defects of under-filling and folding. The material flow interference in the radial and the axial directions at the corner areas is the main reason of the occurrence of defects. A multi-stage cold forging process was proposed to control the material flow and volume distribution simultaneously. FEM simulations were carried out to evaluate the designs of process and die. The proposed preform and web geometry designs were able to decrease the forging load and control the material flow. The simulation results showed the proposed methods were able to make this forged part without defects.

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Sheng, Sun, and Luan Yi Guo. "Preform design of axisymmetric forgings based on reverse simulation technique of die forging process." Journal of Materials Processing Technology 34, no. 1-4 (September 1992): 349–56. http://dx.doi.org/10.1016/0924-0136(92)90127-e.

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Konstantinov, I. L., P. G. Potapov, S. B. Sidelnikov, D. S. Voroshilov, Yu V. Gorokhov, and V. P. Katryuk. "Computer simulation of the technology for AK4-1 alloy die forging production for an internal combustion engine piston." Izvestiya Vuzov. Tsvetnaya Metallurgiya (Universities' Proceedings Non-Ferrous Metallurgy), no. 6 (December 16, 2020): 24–31. http://dx.doi.org/10.17073/0021-3438-2020-6-24-31.

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The process of hot die forging of AK4-1 aluminum alloy billets for the piston of an internal combustion engine (ICE) for an unmanned aerial vehicle (UAV) was simulated using the Deform-3D software package. The object of research was an ICE piston mounted on one of the UAV types of Russian production. Simulation was performed using the following parameters: tooling and billet temperature was 450 °C, ambient temperature was 20 °C, punch speed was 5 mm/s, and Siebel friction index was 0.4. Rigid plastic medium was chosen as a material model. The number of elements (6000) was selected so that at least 3 elements fit in the narrowest section of the part. Thus, as illustrated by the piston die forging, computer simulation in the Deform-3D software makes it possible to develop hot die forging processes for making aluminum alloy billets for UAV ICE pistons. At the same time, computer simulation can be used to evaluate the power parameters of the hot die forging process, study the nature of billet forming in die forging, make necessary adjustments to the virtual process, and develop the design of a die forging tool in order to select the most effective process solutions when designing a real process. The described computer simulation technique can be extended to other aluminum alloy die forgings.

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Balzer, Mario, and Thomas Witulski. "Thermomechanical process route to achieve high fracture toughness in Ti-17 forgings for high temperature applications." MATEC Web of Conferences 321 (2020): 13001. http://dx.doi.org/10.1051/matecconf/202032113001.

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Mechanical properties of Ti-17 are typically strongly influenced by different thermomechanical process parameters such as applied strain, cooling rates and heat treatment temperatures and times. A variation of theses parameters allows the optimization of material properties. Today Ti-17 is mainly used for aero engine applications, where a high strength and good low cycle fatigue properties are needed up to 450°C. For structural parts damage tolerance properties are the main focus and therefore fracture toughness and fatigue crack propagation are the main driving factors for the design. In large forgings such as aero structural parts, the tempering cross section generally varies significantly, which makes it extremely challenging to achieve uniform properties in each area of the forging especially in case of low buy-to-fly ratio. The aim of this work is to develop a robust thermomechanical processing route for large Ti-17 die forgings with complex geometry and high fracture toughness requirements. Hand forging trials with four different thermomechanical processing routes resulting in a lamellar microstructure have been performed and their strength and fracture toughness properties were studied. In addition, one die forging using a promising process route was manufactured and strength and fracture toughness were compared with values typically achieved for Ti6-4.

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KANG, GYUNG JU, JEONG KIM, BEOM SOO KANG, and BYUNG YOUNG MOON. "ANALYSIS AND DESIGN OF PINION WITH INNER HELICAL GEAR BY FEM." International Journal of Modern Physics B 22, no. 09n11 (April 30, 2008): 1859–64. http://dx.doi.org/10.1142/s0217979208047535.

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Cold forging of pinion gear with shape of outer spur gear and inner helical gear have been investigated in this study. A numerical analysis for preform design substituting cutting process in gear forging was developed by means of upsetting process. By using the finite element program DEFORM-3D, the analysis is carried out. Using this simulation, the preform of pinion and helical gear forging process were designed. The suggested process is verified by experiment. Compared to the traditional CNC processing, the upsetting process can form a preform without cutting, which leads to shorter forming time and reduce material usage.

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Jiang, Yin Fang, Yi He, and Yan Ling Lai. "Research on the Converse Design of Aluminum Alloy Connecting-Rod Slab Based on Casting-Forging Coordinates Process." Applied Mechanics and Materials 44-47 (December 2010): 153–57. http://dx.doi.org/10.4028/www.scientific.net/amm.44-47.153.

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It is very important that the shape and size of the slab is designed for forging quality in casting-forging coordinate process. The converse design of aluminum alloy connecting-rod slab is investigated. First, the initial structure of the connecting rod slab is designed, then its forging process is simulated by the software DEFORM, modifying and optimizing the initial structure according to the problems in the analysis, and the slab's casting process is simulated. The converse design reduces the blindness in the slab design process, shorts the designed cycle, and ensures the consistency between slab and the final forging better.

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