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Journal articles on the topic 'Open-Die Forging'

Author: Grafiati

Published: 4 June 2021

Last updated: 5 February 2022

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1

Dindorf, Ryszard, Jakub Takosoglu, and Piotr Wos. "Prediction of the parameters and the hot open die elongation forging process on an 80 MN hydraulic press." Open Engineering 11, no. 1 (January 1, 2021): 528–34. http://dx.doi.org/10.1515/eng-2021-0056.

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Abstract The main task of the study was to develop and implement predictive control in the hot open die forging process of heavy, large, and hard deformable steel forgings on an 80 MN hydraulic press at the Forged Products Department (FPD) of Celsa Huta Ostrowiec (CHO). The predicted hot flow stresses and the predicted deformation/forging forces as a function of the parameters of the elongation forging process were determined. The predicted parameters of the forging process were included in the dynamic model of the hydraulic forging press. Generalized predictive control (GPC) algorithm of the hot open-die forging process on the hydraulic press was developed. The use of predictive control solved the uncertainty of the hot open forging process, which depends on the dimensions, shapes, and material properties of the forgings, as well as the parameters of the hydraulic press and forging tools.

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2

Dindorf, Ryszard, and Piotr Wos. "Energy-Saving Hot Open Die Forging Process of Heavy Steel Forgings on an Industrial Hydraulic Forging Press." Energies 13, no. 7 (April 2, 2020): 1620. http://dx.doi.org/10.3390/en13071620.

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The study deals with the energy-saving process of hot open die elongation forging of heavy steel forgings on an 80 MN industrial hydraulic forging press. Three innovative energy-saving power supply solutions useful for industrial hydraulic forging presses were analyzsed. The energy-saving power supply of hydraulic forging presses consists in reducing electricity consumption by the electric motor driving the pumps, reducing the noise emitted by pumps and reducing leaks in hydraulic piston cylinders. The predicted forging force as a function of heavy steel forging heights for various deformation temperatures and strain rates was determined. A simulation model of the 80 MN hydraulic forging press is presented, which is useful for determining the time-varying parameters during the forging process. An energy-saving control for the hydraulic forging press based on the forging process parameters’ prediction has been developed. Real-time model predictive control (MPC) was developed based on multiple inputs multiple outputs (MIMO), and global predictive control (GPC). The GPC has been implemented in the control system of an 80 MN industrial hydraulic forging press. The main advantage of this control system is the repeatability of the forging process and minimization of the size deviation of heavy large steel forgings

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3

Kwon, Yongchul, Sangsik Kim, and Jonghun Kang. "Study on the cavity closure behavior of steel ingots during open die forging." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 233, no. 13 (April 3, 2019): 2447–57. http://dx.doi.org/10.1177/0954405419840562.

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The manufacturing of sound forgings from large steel ingots requires that internal cavity defects generated during the steel ingot solidification process be compressed by open die forging. The forging ratio that is generally recommended to remove internal defects in large forged products is 3S (threefold); however, the practice lacks a theoretical basis. In this study, a forging experiment and a finite element analysis were performed to investigate the correlation between the forging ratio for large steel ingots (3S) and the cavity closure behavior. First, a hot compression experiment was performed by varying the temperature and strain rate, and the flow stress data observed in the experiment was applied to the finite element analysis. In the experiment for the cogging process, the forging ratio was applied to an actual non-compressive defect material. The finite element analysis was performed using the same forging path as the forging experiment. In the cogging experiment, cavity closure was found by ultrasonic inspection at the forging ratio of 2.9S. The finite element analysis showed that the size of the cavity was significantly decreased at the forging ratio of 2.9S. A finite element analysis was also performed to investigate effective strain and hydrostatic stress at the forging ratio of 2.9S. Finally, this article provides the theoretical basis for the limitation of the internal defect size in initial materials, the threshold effective strain, and the limiting forging ratio of forged products to ensure the internal soundness of large forged products.

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4

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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5

Metelmann, Isabella B., Annett Oltmans, and Sebastian Kraemer. "Isolated open bronchus fracture after open die forging." Trauma Case Reports 32 (April 2021): 100460. http://dx.doi.org/10.1016/j.tcr.2021.100460.

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6

Shirizly, A., J. Tirosh, and L. Rubinski. "Open die forging of porous materials." Materials Science and Engineering: A 249, no. 1-2 (June 1998): 55–61. http://dx.doi.org/10.1016/s0921-5093(98)00563-2.

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7

Wolfgarten, Martin, Dirk Rosenstock, Jan Freitag, and Gerhard Hirt. "Experimental and Numerical Investigation on Controlling the Material Flow in Open-Die Forging through Superimposed Manipulator Displacements." Key Engineering Materials 651-653 (July 2015): 272–77. http://dx.doi.org/10.4028/www.scientific.net/kem.651-653.272.

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In the past, different methods have been investigated regarding the production of curved workpieces by open-die forging as a significant demand for open-die forged parts with excellent mechanical properties exists. Current ways to produce curved workpieces by open-die forging have the disadvantages of complex preforms and inflexibility. One alternative approach to realize the production of curved workpieces by open-die forging is to actively control the material flow in open-die forging by superimposed manipulator movements during a forging stroke. Since the currently formed material between the forging dies is in a plastic state during the deformation, the required bending forces can be reduced significantly. This concept is investigated in a first study for the cold-forging of an aluminum alloy by numerical simulation and experiments on laboratory scale. For the process, the bite ratio, height reduction and the intended bending angle were identified as most important process parameters. Both numerical and experimental investigation proved the feasibility of the process principle since the bending forces, moments and the bending work can be reduced significantly.

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8

Liang, Jin Tao, Sheng Dun Zhao, and Jian Wang Zhao. "A Novel Dimension Measurement System of Hot Large Open Die Forgings." Advanced Materials Research 291-294 (July 2011): 2728–32. http://dx.doi.org/10.4028/www.scientific.net/amr.291-294.2728.

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In this paper, based on the analysis of the problem about manual measure for hot large open die forings and the significance for realizing noncontact online measure, a novel dimension measurement system of hot large open die forgings is presented. Laser ranging method is used for measuring axial dimension and binocular vision method is used for measuring radial dimension, so that the system characterized by large size, automated, fast response and high precision which benefits high efficiency and low material loss in open die forging process.

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9

Lazorkin, Viktor. "New Four-Die Forging Devices (FDFD) Design Solutions and Open-Die Forging Technologies." Advances in Materials 7, no. 1 (2018): 1. http://dx.doi.org/10.11648/j.am.20180701.11.

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10

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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11

Christiansen, Peter, Jesper H. Hattel, Niels Bay, and Paulo AF Martins. "Physical modeling and numerical simulation of V-die forging ingot with central void." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 228, no. 13 (January 16, 2014): 2347–56. http://dx.doi.org/10.1177/0954406213517878.

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Numerical simulation and physical modeling performed on small-scale ingots made from pure lead, having a hole drilled through their centerline to mimic porosity, are utilized to characterize the deformation mechanics of a single open die forging compression stage and to identify the influence of the lower V-die angle on porosity closure and forging load requirements of large cast ingots. Results show that a lower V-die angle of 120° provides the best closure of centerline porosity without demanding the highest forging loads or developing unreasonably asymmetric shapes that may create difficulties in multi-stage open die forging procedures.

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12

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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13

Banaszek, Grzegorz, Teresa Bajor, Anna Kawałek, and Tomasz Garstka. "Analysis of the Open Die Forging Process of the AZ91 Magnesium Alloy." Materials 13, no. 17 (September 2, 2020): 3873. http://dx.doi.org/10.3390/ma13173873.

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The paper presents the results of numerical modelling of the forging process of magnesium alloy ingots on a hydraulic press with the use of flat and shaped anvils. The use of shaped (rhombic-trapezoid) anvils will affect the uniform distribution of temperature and strain intensity in the entire volume of the forging, causing a number of forging passes, which in consequence will reduce the costs of the blank manufacturing process. However, higher values of the strain intensity were obtained during the deformation of the material in flat anvils. The purpose of the research was to propose assumptions for forging technology of producing a blank from AZ91 alloy with the use of flat and shaped anvils. Numerical examination for AZ91 magnesium alloy was carried out using the Forge®NxT commercial software. The rheological properties of the investigated alloy were determined on the basis of uniaxial compression tests carried out in the Gleeble 3800 metallurgical simulation system. The numerical analysis of the process of forging AZ91 alloy ingots on a press was conducted in the temperature range of 200–400 °C and at several forging passes.

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14

Kim, P. H., M. S. Chun, J. J. Yi, and Y. H. Moon. "Pass schedule algorithms for hot open die forging." Journal of Materials Processing Technology 130-131 (December 2002): 516–23. http://dx.doi.org/10.1016/s0924-0136(02)00798-7.

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15

Dudra, Steve P., and Yong-Taek Im. "Analysis of void closure in open-die forging." International Journal of Machine Tools and Manufacture 30, no. 1 (January 1990): 65–75. http://dx.doi.org/10.1016/0890-6955(90)90042-h.

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16

Kiefer, B. V., and K. N. Shah. "Three-Dimensional Simulation of Open-Die Press Forging." Journal of Engineering Materials and Technology 112, no. 4 (October 1, 1990): 477–85. http://dx.doi.org/10.1115/1.2903360.

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A three-dimensional, large deformation elastic-plastic finite element model is used to study the distribution of internal stresses and strains which occur during the forging process. Simulations are carried out on a rectangular ingot, using conventional dies which are flat and symmetrical top and bottom, to study the effects of die width and amount of reduction. A comparison is then carried out between the conventional dies and FML dies, which are also flat but of differing size on top and bottom. Also, a brief study is made of the effects of temperature gradients from ingot surface to core when forged with both types of dies.

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17

Elzey, D. M., and H. N. G. Wadley. "Open-die forging of structurally porous sandwich panels." Metallurgical and Materials Transactions A 30, no. 10 (October 1999): 2689–99. http://dx.doi.org/10.1007/s11661-999-0309-0.

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18

Gupta, Rohit Kumar, Bhanu Pant, Vijaya Agarwala, and Parameshwar Prasad Sinha. "Hot Working of Ti Aluminide Made through Reaction Synthesis." Materials Science Forum 710 (January 2012): 137–42. http://dx.doi.org/10.4028/www.scientific.net/msf.710.137.

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Hot working of titanium aluminide made through reaction synthesis (RS) has been studied. Hot isostatic pressing under argon, isothermal pressing under vacuum, open die forging and pack forging was carried out. Hot worked billet samples were characterized for density and microstructure evolution. Presence of refined grains and dynamically recrystallized grains were observed. In case of open die forging, presence of twins was also found. From the present study, near isothermal working through near conventional processes has been confirmed. However, role of isothermal working in obtaining crack free sound deformed product has also been noted.

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19

Hou, Jiaoyi, Zengmeng Zhang, Hua Zhou, Dayong Ning, and Yongjun Gong. "Hydraulic systems control based on the characteristics of major-motion mechanism for an open-die forging manipulator." Advances in Mechanical Engineering 9, no. 2 (February 2017): 168781401769095. http://dx.doi.org/10.1177/1687814017690959.

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In the open-die forging process, the forging manipulator must cooperate closely with the forging press. Terrible working conditions of open-die forging have resulted in significant demand on the hydraulic control systems of the forging manipulator. This article analyzes the characteristics of major-motion hydraulic systems with the aim of proposing a novel hybrid serial–parallel heavy-duty forging manipulator. Kinematic and dynamic models of the major-motion mechanism are developed to investigate the control and comply with performance of hydraulic lifting, pitching, and buffering systems. Simulation shows that the three hydraulic systems are coupled in the position and posture control of the clamp. A separate posture control method based on the characteristic of the major-motion mechanism is designed for the hydraulic systems, and the position tracking performance of the hydraulic systems is studied in a stretching process of a plat-tool.

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20

RIEDEL, Mirko, Torben WIESE, Arvid HELLMICH, and Steffen IHLENFELDT. "FAST AND COST EFFICIENT MEASURING OF GEOMETRY AND TEMPERATURE FOR OPEN-DIE FORGING." Journal of Machine Engineering 19, no. 3 (September 15, 2019): 83–94. http://dx.doi.org/10.5604/01.3001.0013.4085.

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In open-die forging it is state of the art to use simulation tools for creating forging plans and setpoint values for the forging press and the automated part manipulator. These forging plans define required positions and forces. Therefore, the process can be fully automated. However, even small variations of not considered influence parameters lead to different forging results and thus to a discontinuous process. Influencing factors are, e.g. material parameter deviations, uncertainties in force measurements or variations in the part temperature due to varying environmental conditions. This paper presents an approach for a fully automatic open-die forging process with respect to actual conditions, based on a parallel measurement of the workpiece geometry and temperature and a “process-real-time” adaptation on the controller system. The focus of this work is the development of a measuring strategy and an according sensor setup for the combined temperature and geometry measurement of the workpiece. In addition, the structure, the characteristic features of the components and the beam path of the sensors scanning units are shown. Furthermore, first experimental results for the alignment of the beam path are presented. In the outline, the setup and calibration strategy of the measurement system are stated.

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21

Kajikawa, Shohei, Takashi Iizuka, and Keisuke Yamaishi. "Displacement Behavior of Wood in Boss Forming Using Open-Die Wood Forging." Key Engineering Materials 504-506 (February 2012): 1261–66. http://dx.doi.org/10.4028/www.scientific.net/kem.504-506.1261.

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Biomass materials such as wood are attracting renewed attention as alternative fuels in order to help resolve environmental resources caused by the use of fossil fuels. In this study, the possibility of products being processed from wood bulk was investigated by means of boss forming using open-die forging. Additionally, the difference in formability and deformation behavior during forging was investigated by changing the experimental conditions, such as the moisture content of the wood billets used, the forming pressure, and the forming temperature. The experimental results showed that wood had enough liquidity to be forged, and that two sudden and large increases in displacement occur during forging. Finally, the conditions governing these displacements were summarized from these results

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22

Kim, S. H., M. C. Lee, S. M. Jang, J. G. Eom, and M. S. Joun. "Comparative Study on Pore Closing in Open Die Forging by Conventional Forging Press and Radial Forging Machine." Transactions of Materials Processing 19, no. 7 (November 1, 2010): 399–404. http://dx.doi.org/10.5228/kstp.2010.19.7.399.

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23

Sagar, R., and B. L. Juneja. "Open die forging of a four sided irregular disc." International Journal of Machine Tools and Manufacture 31, no. 3 (January 1991): 315–28. http://dx.doi.org/10.1016/0890-6955(91)90078-h.

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24

Kotous, Jakub, Václav Kubec, Michal Duchek, and Tomáš Studecký. "Optimization of workability technological testing for open-die forging." IOP Conference Series: Materials Science and Engineering 723 (February 25, 2020): 012015. http://dx.doi.org/10.1088/1757-899x/723/1/012015.

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25

Knap, Matjaž, Goran Kugler, Heinz Palkowski, and Radomir Turk. "Prediction of Material Spreading in Hot Open-Die Forging." steel research international 75, no. 6 (June 2004): 405–10. http://dx.doi.org/10.1002/srin.200405787.

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26

Överstam, Henrik, and Magnus Jarl. "FEM-Simulation of Drawing Out in Open Die Forging." steel research international 75, no. 12 (December 2004): 812–17. http://dx.doi.org/10.1002/srin.200405847.

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27

Shiau, Y. C., and S. Kobayashi. "Three-dimensional finite element analysis of open-die forging." International Journal for Numerical Methods in Engineering 25, no. 1 (January 1988): 67–85. http://dx.doi.org/10.1002/nme.1620250108.

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28

Irisarri, A. M., and A. Pelayo. "Failure analysis of an open die forging drop hammer." Engineering Failure Analysis 16, no. 5 (July 2009): 1727–33. http://dx.doi.org/10.1016/j.engfailanal.2008.12.008.

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29

Jabbari, Ali, Seyed Sajjad Kiani, and Mahdi Rasafchi. "Mitigation of Barreling Defect in Open Die Forging Process." Journal of Mechatronics 3, no. 1 (March 1, 2015): 33–36. http://dx.doi.org/10.1166/jom.2015.1083.

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30

Recker, D., M. Franzke, and G. Hirt. "Fast models for online-optimization during open die forging." CIRP Annals 60, no. 1 (2011): 295–98. http://dx.doi.org/10.1016/j.cirp.2011.03.142.

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31

KONG, FANXIN, JIANMIN ZUO, GUANGCHENG ZHA, and JIAO ZHANG. "STUDY AND APPLICATION OF OPEN DIE FORGING CAPP SYSTEM BASED ON PROCESS KNOWLEDGE." Journal of Advanced Manufacturing Systems 10, no. 01 (June 2011): 45–52. http://dx.doi.org/10.1142/s0219686711001965.

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This paper discusses concepts and methods related to CAPP (Computer Aided Process Planning) system based on process knowledge. The CAPP system framework module of Open Die Forging facing industry is proposed. This module can realize the fusion of retrieval type, derived type, and creative type, etc. CAPP functions, reasons and makes decision based on knowledge and, develops the optimal process route, and process card. In this paper, the main functions of the system are introduced based on developments of open die forging CAPP system in recent years.

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32

Frazier, W. G., T. Seshacharyulu, S. C. Medeiros, and Y. V. R. K. Prasad. "Control of Transient Thermal Response During Sequential Open-Die Forging: A Trajectory Optimization Approach." Journal of Manufacturing Science and Engineering 124, no. 3 (July 11, 2002): 502–8. http://dx.doi.org/10.1115/1.1467076.

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A trajectory optimization approach is applied to the design of a sequence of open-die forging operations in order to control the transient thermal response of a large titanium alloy billet. The amount of time the billet is soaked in furnace prior to each successive forging operation is optimized to minimize the total process time while simultaneously satisfying constraints on the maximum and minimum values of the billet’s temperature distribution to avoid microstructural defects during forging. The results indicate that a “differential” heating profile is the most effective at meeting these design goals.

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33

Hu, Dao Chun, and Lei Wang. "Cold Forging Process Analysis and Precision Progressive Die for Cam of Low-Carbon Steel." Applied Mechanics and Materials 44-47 (December 2010): 2733–36. http://dx.doi.org/10.4028/www.scientific.net/amm.44-47.2733.

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This paper analyzes the forming process methods of cam in CPU socket to control its open and close. The whole process is pierce, notch, the first forging forming, the second pierce(the second pilot hole), the second forging forming(sizing), impact forging forming, and trimming. The punch shape design of the first forging forming is simulated by finite element analysis. The optimized punch profile radius 0.50mm and punch size Φ10.60mm are available. Cold forging of precision progressive die is put forward. The second pierce pilot hole that newly designed is applied, which relief the deformation of pilot holes caused by severe metal flow. Compared with the traditional single operation dies, the precision progressive die based on cold forging process were proved through the practical production to be high economical efficiency, which could be the references for developing the cold forging process of producing the similar produsts.

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34

Tamura, K., and J. Tajima. "Optimization of open-die forging process design to ensure homogeneous grain size refinement of cast structures by three-dimensional rigid-plastic finite element analysis." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 218, no. 9 (September 1, 2004): 931–46. http://dx.doi.org/10.1243/0954406041991305.

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Focusing on the rough-forging stage of the hot open-die forging process, the influence of pass schedule on the equivalent plastic strain distribution at the surface of a forged billet has been numerically analysed using a three-dimensional rigid-plastic finite element method. By analysing the circumferential distribution of the strain obtained by one forging pass, it has been clarified that the distribution is strongly influenced by the cross-sectional shape of a workpiece. By utilizing the analytical results, a new method has been developed to predict the cross-sectional shape and the strain distribution without numerically analysing all passes. As a result, a new pass schedule has been proposed to ensure homogeneous grain size refinement of cast structures and the effect of the pass schedule was verified by a real hot open-die forging experiment.

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35

Di Schino, Andrea. "Open die forging process simulation: a simplified industrial approach based on artificial neural network." AIMS Materials Science 8, no. 5 (2021): 685–97. http://dx.doi.org/10.3934/matersci.2021041.

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<abstract> <p>Simulations by Finite element analysis (FEM) of open die forging process related to different configurations are quite common in industry to optimize the process. This approach, anyway, is relatively slow to be performed: hence it is not suitable for online optimization of the forging processes. In this paper a simplified approach is proposed aimed to describe the plastic strain at the core of the forged component. The proposed approach takes into account the plastic deformation at the core of the forged component and consists on a thermo-mechanical FEM model implementation allowing to define a set of equations giving as output the plastic strain at the core of the piece as a function of the forging parameters. An Artificial Neural Network (ANN) is trained and tested aimed to relate the equation coefficients with the forging to obtain the behavior of plastic strain at the core of the piece.</p> </abstract>

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36

Zhao, De Ying, Lian Dong Zhang, and Hui Xue Sun. "Research on Closed Die Forging Process of Car Steering Knuckle." Materials Science Forum 575-578 (April 2008): 204–9. http://dx.doi.org/10.4028/www.scientific.net/msf.575-578.204.

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Steering knuckle, which has strict requirements with regard to dimensional precision and quality, is a key component in cars. Conventional plastic forming methods are involved with intricate procedures and high energy consumptions. Normally, a 40 MN hot die forging press or a 100 KJ electro-hydraulic hammer is required to produce the steering knuckle. Closed die forging, which is a new precision forming technology developed in recent years, has some virtues, such as good mechanical properties, easy to form and improving of metal plastic deformation. Aiming at Jetta steering knuckle in this paper, the technology of two forging steps in one heat is presented. This technology is mainly composed of precision pre-forging, which is a closed die extrusion with the extrusion belt, and open finish-forging. The pre-forging process and finish-forging process are numerically simulated using the FEM software DEFORM-3D. For the closed die extrusion forming process, which is the key component of the technology, some key problems were researched, such as the flowing and filling regularity, extrusion-belt length, punch size, punch movement, lubrication and the relationship between the clamping pressure and the extrusion pressure. For the finish-forging process, the flowing and filling regularity of the finish-forging part was studied to verify the correct shape and dimension of the pre-forging part. Numerical simulation with regard to the pre-forging process shows that the closed die forging can not only help to form the pre-forging part, but also decrease the extrusion pressure to be less than 8 MN, extend the mould’s service life and increase the utilization ratio of materials to be more than 75%. Numerical simulation of the finish-forging process shows that the pre-forging part design is rational. In addition, the forging experiments were carried out using the dies designed in particular. The experiments show that the technology is feasible and can markedly improve the mechanical property of the forging piece.

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Verma, Deep, P. Chandrasekhar, S. Singh, and S. Kar. "Investigations into Deformation Characteristics during Open-Die Forging of SiCp Reinforced Aluminium Metal Matrix Composites." Journal of Powder Technology 2013 (October 10, 2013): 1–14. http://dx.doi.org/10.1155/2013/183713.

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The deformation characteristics during open-die forging of silicon carbide particulate reinforced aluminium metal matrix composites (SiCp AMC) at cold conditions are investigated. The material was fabricated by liquid stir casting method in which preheated SiC particles were mixed with molten LM6 aluminium casting alloy and casted in the silicon mould. Finally, preforms obtained were machined in required dimensions. Two separate cases of deformation, that is, open-die forging of solid disc and solid rectangular preforms, were considered. Both upper bound theoretical analysis and experimental investigations were performed followed by finite element simulation using DEFORM, considering composite interfacial friction law, barreling of preform vertical sides, and inertia effects, that is, effect of die velocity on various deformation characteristics like effective stress, strain, strain rate, forging load, energy dissipations, and height reduction. Results have been presented graphically and critically investigated to evaluate the concurrence among theoretical, experimental, and finite element based computational findings.

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Lakshmipathy, R., and R. Sagar. "Effect of die surface topography on die-work interfacial friction in open die forging." International Journal of Machine Tools and Manufacture 32, no. 5 (October 1992): 685–93. http://dx.doi.org/10.1016/0890-6955(92)90023-a.

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Hung, Chinghua, and Shiro Kobayashi. "Three-Dimensional Finite Element Analysis on Open-Die Block Forging Design." Journal of Engineering for Industry 114, no. 4 (November 1, 1992): 459–64. http://dx.doi.org/10.1115/1.2900698.

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Three-dimensional rigid-plastic finite element method was used to analyze the practice of open-die block forging, focusing on the effects of die configurations and forging pass designs. Four combinations of die configurations were investigated: conventional flat dies, top flat/bottom V-shaped dies, and double V-shaped dies with 120 and 135 deg included angles. Two different pass designs, 90 and 180 deg rotation angles between succeeding passes, were applied to each die set. The results include the magnitude and distribution of effective strains along the center line of the cylindrical workpiece and the final shape of the workpiece. Good agreement was observed in comparison with experimental data from physical modeling method, and several suggestions were made for choosing suitable dies.

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Li, Jun, Zhi Shou Zhu, Xin Nan Wang, Yue Fei, Guo Qiang Shang, and Li Wei Zhu. "Research on Effects of Uneven Macrostructure to Mechanical Properties in TC21 Forging." Materials Science Forum 747-748 (February 2013): 823–27. http://dx.doi.org/10.4028/www.scientific.net/msf.747-748.823.

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The microstructure, tensile properties, fracture toughness, fatigue crack growth rate and fatigue limit of different macrostructure regions in TC21 open-die forging were investigated. The results show that the microstructure is also uneven corresponding to non-uniform macrostructure. The ultimate tensile strength (UTS) and yield strength (YS) of coarse-grained zone are that UTS1070MPa, YS960MPa, which can meet the requirement of technical standard, whereas the strength of fine-grained zone drops more than 100MPa. The fracture toughness of this forging is that KIC90MPa·m1/2, being equivalent to the normal one. But when K=11MPa·m1/2, the fatigue crack growth rate is that da/dN=2.488758×10-5mm/cycle, higher than the normal TC21 open-die forging for an order of magnitude. The fatigue limit of fine-grained zone drops about 40MPa compared with coarse-grained zone. Uneven macrostructure and microstructure lead to a decline of tensile and fatigue property in TC21 forging.

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KISHIMOTO, Atsushi, Takefumi ARIKAWA, Yasunori KAGAWA, and Hiroshi TAKAHARA. "Consolidation of Voids in Open Die Forging Using Steel Ingot." Journal of the Japan Society for Technology of Plasticity 60, no. 701 (2019): 167–74. http://dx.doi.org/10.9773/sosei.60.167.

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42

Hauri, Janine, Marcel Graf, Birgit Awiszus, and Rudolf Kawalla. "Closing of Shrinkage Cavities by Means of Open-Die Forging." Materials Science Forum 918 (March 2018): 77–84. http://dx.doi.org/10.4028/www.scientific.net/msf.918.77.

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Inner cavities in cast ingots have to be closed by means of open-die forging to guarantee the integrity of the forged components during usage. In the paper a differentiation is made between the macroscopic and the microscopic closing of natural inner cavities. Special attention is paid to the dendritic structure of the surfaces of inner cavities and their impact on the microscopic closing behavior. Additionally, investigation showed that a closing on the microscopic scale is only possible if the cavities do not come in contact to the atmosphere during hot forming. For the analysis of the cavity closing, ingots of a heat-treatable, hot-working and a cold-working steel were used. The ingots were cast, forged and the surface of the inner voids was analyzed with the help of light-microscopy, SEM and EDS for the microstructure and by using tensile tests on macroscopic scale. Also, numerical investigations were a part of the work, whereby the parameters void size, void shape and anvil-shape were varied. As a result of the numerical investigation, a so called closing function was formed. This function enables the user to calculate the necessary height-reduction for closing of inner cavities of the regarded ingot format.

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Lee, Young Seon, Y. C. Kwon, Yong Nam Kwon, Jung Hwan Lee, S. W. Lee, and N. S. Kim. "Analysis on Void Closure Behavior during Hot Open Die Forging." Advanced Materials Research 26-28 (October 2007): 69–72. http://dx.doi.org/10.4028/www.scientific.net/amr.26-28.69.

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

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Aksakal, B., F. H. Osman, and A. N. Bramley. "Upper-bound analysis for the automation of open-die forging." Journal of Materials Processing Technology 71, no. 2 (November 1997): 215–23. http://dx.doi.org/10.1016/s0924-0136(97)00078-2.

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Mamalis, A. G., G. L. Petrossian, and D. E. Manolakos. "Open-die forging of sintered cylindrical billets: an analytical approach." Journal of Materials Processing Technology 96, no. 1-3 (November 1999): 112–16. http://dx.doi.org/10.1016/s0924-0136(99)00266-6.

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Zahalka, Martin. "Modal Analysis of Hydraulic Press Frames for Open Die Forging." Procedia Engineering 69 (2014): 1070–75. http://dx.doi.org/10.1016/j.proeng.2014.03.092.

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Baglyuk, G. A. "Modeling deformation of a porous blank in open-die forging." Powder Metallurgy and Metal Ceramics 36, no. 9-10 (September 1997): 459–61. http://dx.doi.org/10.1007/bf02680491.

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Li, Lu, and Fang Wang. "Comparative Study of Different Types of Flashes on the Flange Open-Die Forging." Advanced Materials Research 683 (April 2013): 635–38. http://dx.doi.org/10.4028/www.scientific.net/amr.683.635.

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The type of flash has great influence on the open-die forging. Comprehensive performance of different types of flashes in the same part is analyzed by the finite element method. Comparative Studies show that the resistance wall structure has the optimal filling performance, the expansion-shaped flash has the minimum deformation load and tool wear depth and the typical structure has excellent overall performance in the studied flange forging with narrow rib and deep cavity. These results are significant to the theoretical research and practical applications.

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Reinisch, Niklas, Fridtjof Rudolph, Stefan Günther, David Bailly, and Gerhard Hirt. "Successful Pass Schedule Design in Open-Die Forging Using Double Deep Q-Learning." Processes 9, no. 7 (June 22, 2021): 1084. http://dx.doi.org/10.3390/pr9071084.

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In order to not only produce an open-die forged part with the desired final geometry but to also maintain economic production, precise process planning is necessary. However, due to the incremental forming of the billet, often with several hundred strokes, the process design is arbitrarily complicated and, even today, often only based on experience or simple mathematical models describing the geometry development. Hence, in this paper, fast process models were merged with a double deep Q-learning algorithm to enable a pass schedule design including multi-objective optimization. The presented implementation of a double deep Q-learning algorithm was successfully trained on an industrial-scale forging process and converged stably against high reward values. The generated pass schedules reliably produced the desired final ingot geometry, utilized the available press force well without exceeding plant limits, and, at the same time, minimized the number of passes. Finally, a forging experiment was performed at the institute of metal forming to validate the generated results. Overall, a proof of concept for the pass schedule design in open-die forging via double deep Q-learning was achieved which opens various starting points for future work.

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LEE, SUNG-UK, and DONG-YOL YANG. "TOOL PATH DESIGN OF INCREMENTAL OPEN-DIE DISK FORGING USING PHYSICAL MODELING." International Journal of Modern Physics B 22, no. 31n32 (December 30, 2008): 5686–91. http://dx.doi.org/10.1142/s0217979208051017.

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A small-batch product of large-sized parts is usually manufactured using incremental open-die forging. In order to control the overall change in the shape of a part, it is essential to be able to predict the shape changes that occur during each step. This paper addresses shape changes of a material according to the forging path. Rapid prediction of metal flows for continuing incremental deformation using theoretical methods is difficult. Accordingly, instead of a theoretical approach, an experiment that tests the tendency of the metal flow for development of forming processes is required. For the sake of convenience, simulative experiments are carried out using plasticine at room temperature. In present study, the tool movement is dominant parameters to with respect to changing the shape of the workpiece.

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