Journal articles: 'Roll-forging, Finite Element Analysis, Preforms in Forging'

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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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Gao, Zhen Shan, Xiao Zhong Deng, and Fu Xiao Chen. "A Study on Gear Tooth Metal Flowing Law and Process Optimization of Spiral Bevel Gear Forging." Advanced Materials Research 753-755 (August 2013): 215–20. http://dx.doi.org/10.4028/www.scientific.net/amr.753-755.215.

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Insufficient gear tooth corner filling and high forming load are the main problems in spiral bevel gear forging. In this study, three different preforms were proposed. According to the analysis of the forging spiral bevel gear process using the semi-closed die, which was based on elastoplastic finite element model, the metal flowing law of tooth along tooth alignment and profile are revealed. From the simulation results, the arc face shape preform and the finish die with divided flow cavity are good for forging gear, and an optimized process was presented. Experiments were carried out using electric drive screw press with the rated forming load of 2500 Tons. By analyzing numerical simulations and experimental results, the process mentioned in this paper improves the tooth corner filling and reduces the forming load effectively.

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Tomczak, J., Z. Pater, and T. Bulzak. "Thermo-Mechanical Analysis of a Lever Preform Forming from Magnesium Alloy AZ31 / Termomechaniczna Analiza Kształtowania Przedkuwki Dźwigni Ze Stopu Magnezu AZ31." Archives of Metallurgy and Materials 57, no. 4 (December 1, 2012): 1211–18. http://dx.doi.org/10.2478/v10172-012-0135-z.

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This paper presents the results of numerical analysis of metal forming process of a lever preform from magnesium alloy AZ31, which will be used as a semi-finished product in the forging process of a lever part. Presently, the lever forging is formed from semi-finished product in the form of a bar, which is connected with large material losses. Numerical simulations were made for two different metal forming methods: forging longitudinal rolling and cross-wedge rolling. Calculations were conducted basing on finite element method (FEM), applying commercial software DEFORM-3D. Geometrical models used in calculations were discussed. Simulations, made in conditions of three dimensional state of strain, allowed for determining distributions of strain intensity, temperature, cracking criterion, and mainly for determining the possibility of a lever preform manufacturing on the basis of rolling processes. Considering the obtained results of numerical simulations, the design of tools for semi-finished products rolling was worked out; these semi-finished products will be used for experimental verification of the lever preforms forming.

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Pope, Jacob, and Martin Jackson. "FAST-forge of Diffusion Bonded Dissimilar Titanium Alloys: A Novel Hybrid Processing Approach for Next Generation Near-Net Shape Components." Metals 9, no. 6 (June 4, 2019): 654. http://dx.doi.org/10.3390/met9060654.

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Material reductions, weight savings, design optimisation, and a reduction in the environmental impact can be achieved by improving the performance of near-net shape (NNS) titanium alloy components. The method demonstrated in this paper is to use a solid-state approach, which includes diffusion bonding discrete layers of dissimilar titanium alloy powders (CP-Ti, Ti-6Al-4V and Ti-5Al-5Mo-5V-3Cr) using field-assisted sintering technology (FAST), followed by subsequent forging steps. This article demonstrates the hybrid process route, firstly through small-scale uni-axial compression tests and secondly through closed-die forging of dissimilar titanium alloy FAST preforms into an NNS (near-net shape) component. In order to characterise and simulate the underlying forging behaviour of dissimilar alloy combinations, uni-axial compression tests of FAST cylindrical samples provided flow stress behaviour and the effect of differing alloy volume fractions on the resistance to deformation and hot working behaviour. Despite the mismatch in the magnitude of flow stress between alloys, excellent structural bond integrity is maintained throughout. This is also reflected in the comparatively uncontrolled closed-die forging of the NNS demonstrator components. Microstructural analysis across the dissimilar diffusion bond line was undertaken in the components and finite element modelling software reliably predicts the strain distribution and bond line flow behaviour during the multi-step forging process.

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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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Lei, X., and C. J. Lissenden. "Finite Element Simulation of Ausforming of Austempered Ductile Iron Components." Journal of Manufacturing Science and Engineering 123, no. 3 (October 1, 2000): 420–25. http://dx.doi.org/10.1115/1.1380383.

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The mechanical properties of ductile iron can be improved by ausforming, that is, applying work during austempering. The resulting yield strength and ductility are comparable to those of SAE 4140 steel, while the density is approximately 10 percent less. The viability of manufacturing components by casting a preform, austenitizing it, quenching it to the austempering temperature, forging it, austempering it, and finally, quenching it to the net shape is investigated by simulating the forging operation with finite element analysis. The preform geometry and die set geometry are determined such that the forging operation imparts a reasonably uniform equivalent plastic strain of 20 percent to the workpiece and the prescribed final component geometry is obtained. Forging of two components of varying geometric complexity is simulated using a commercial software package. The results indicate that the geometry of the final part is reasonably close to the goal and that the equivalent plastic strain distribution is reasonably uniform—over 80 percent of the material was plastically deformed 15–25 percent. The design of the preform and die sets appears to be an excellent application for an optimization algorithm.

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Lee, Geun An, Seong Joo Lim, Dong Jin Kim, and Yong Bok Park. "Finite Element Analysis for Precision Forging Process of United Transfer Driven Parking Gear." Materials Science Forum 544-545 (May 2007): 327–30. http://dx.doi.org/10.4028/www.scientific.net/msf.544-545.327.

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Forging process is one of the most basic metal forming processes. In this study a new forging process is applied to fabricate a precision forging product uniting parking and driven gears in order to obtain lightweight and cost effectiveness of an automobile. Since the united product using the precision forging process needs high quality and new manufacturing process, 3D computer simulation by FEM has been used to reduce some trial and errors in experiment and obtain the deformation, strain, stress and load of the workpiece and die. The study has tried to find out an optimal process including preform design putting emphasis on tooth filling by DEFORM-3D, a 3-dimensional rigid-plastic finite element code.

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Li, Ru Xiong, and Song Hua Jiao. "Thermal Coupled FEM Analysis of Precision Roll Forging Performing of Automobile Front Axle." Advanced Materials Research 557-559 (July 2012): 1330–35. http://dx.doi.org/10.4028/www.scientific.net/amr.557-559.1330.

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According to the characters, technological condition and requirements of automotive front axle forging, both the process of exact roll-forging billet and die design are studied, as the result, roll- forging die of front axle billet, pre-completed roll-forging die and final roll-forging die are design respectively, finally the groove with hat cross-section is analyzed and top pressure rolling method is proposed during blank-making roll-forging process. The precision rolling forging performing deformation process of automobile front axle is simulated with finite element software Deform-3D by using 3D thermo-mechanical coupled rigid plastic FEM. The metal flow process, equivalent stress and strain field, temperature field and load status of rolling die are analyzed, and they are consistent with experiments. This provides a dependable theoretical basis for understanding the deforming mechanism and selecting reasonable parameters for the precision rolling forging performing of front axle.

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Oh, Seung Hwan, Joon Hong Park, Kwon Hee Lee, Dong Hun Kang, Xue Guan Song, Jung Ho Kang, and Young Chul Park. "Optimization of Preform in Forging Process Using Kriging Model." Advanced Materials Research 26-28 (October 2007): 977–80. http://dx.doi.org/10.4028/www.scientific.net/amr.26-28.977.

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The welding process, a conventional production method of gate valves, has advantages such as light weight, but it also has disadvantages such high production price. However, the forging process, has economic merits and mass production capability. The main focus of this paper is the optimization of the preform in the forging process. This paper proposes an optimal design of the preform to improve the mechanical efficiency of the gate valve made by the forging method. The design of the preform is optimized by the use of the real response model to the Kriging model by computer simulation. Also, the optimized results were used to verify the response model. The verified response model confirmed the usefulness and reliability of the Kriging method in optimum structural design of preform achieved by finite element analysis and Kriging equations.

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Wangchaichune, Sethapong, and Surasak Suranuntchai. "Finite Element Simulation of Hot Forging Process for KVBM Gear." Applied Mechanics and Materials 875 (January 2018): 30–35. http://dx.doi.org/10.4028/www.scientific.net/amm.875.30.

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In this study, the forging operations of gear has been modeled. This gear is a part which is manufactured with the help of hot forging industry for reduce the cost. The authors propose to reduce the initial billet volume of AISI 4340 steel for the forged through process optimization using the Finite Element (FE)method. The object of this research was to predict the effect of several parameters, such as effective stress, effective plastic strain, temperature and die contact, on the forming of the gear, utilizing computer simulation and experimental results. For this purpose, Solidworks CAD and Simufact Forming FE software were used for the modeling and analysis of the forging process. The billet volume and the preform design were predefined in order to reduce scrap by using preform type C. The experimental results showed that the initial billet volume was reduced at 32 %, which compared favorably with the simulation result of a 40 % reduction. The maximum preforming force of simulation result was diferent with the experiment result at 18 along with the maximum finishing force of simulation result was different with the experiment result at 11 %. It was also found that the effective stress decreased with increasing the temperature, and the press force decreased when the initial billet volume was decreased, which resulted in a decrease of effective plastic strain as well.

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Shao, Yong, Ping Yi Guo, Zhi An Liu, Zhao Yu Zhou, and Wei Cai. "Influence of Cross Section Shapes of Preformed Blade Body for Final Forging Formability Based on Numerical Simulation." Advanced Materials Research 189-193 (February 2011): 2558–61. http://dx.doi.org/10.4028/www.scientific.net/amr.189-193.2558.

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During the preform design of blade body, the final forging process for blade body with different transverse cross section shapes coupled different twist angles along blade body are simulated by using DEFORM-2D finite element analysis software. The final forging quality effected by different perform structures of blade body are analyzed in details through comparing some key factors such as formability, deformation uniformity, loss of heat before deformation. The valuable references are obtained for further design of optimizing blade body shape.

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dos Santos Freitas, Maria Carolina, José Adilson de Castro, Luciano Pessanha Moreira, and Flávia de Paula Vitoretti. "Densification Behaviour Modelling for Metallic Powders." Materials Science Forum 802 (December 2014): 317–22. http://dx.doi.org/10.4028/www.scientific.net/msf.802.317.

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Powder forming involves fabrication of a preform by conventional press-and-sinter processing, followed by various forming processes, citing as examples, rolling, compaction, forging, extrusion, among others, of the porous preform into a final shape through substantial densification. This work makes a finite element analysis for porous metals. The finite element model was applied to simulating the case of compaction of nanocristalline copper under uniaxial compression conditions in order investigate the densification behavior. The model was simulated using explicit integration method as applied to the evolution variation of the relative density and the dislocation density of the compact. Finite element analysis program used was Abaqus. Finite element calculations were compared with literature data. The agreements between finite element model and literature results for densification of nanocristalline copper were good.

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Saquib, A. N., H. M. T. Khaleed, Irfan Anjum Badruddin, Ali Algahtani, M. F. Addas, A. B. Abdullah, Abdulgaphur Athani, Sarfaraz Kamangar, and T. M. Yunus Khan. "Development of Preform for Simulation of Cold Forging Process of A V8 Engine Camshaft Free from Flash & Under-Filling." Mathematics 7, no. 11 (October 31, 2019): 1026. http://dx.doi.org/10.3390/math7111026.

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Finite Element Method based techniques apply to a wide spectrum of engineering applications including manufacturing. The flexibility to achieve optimized results by simulations adds another dimension to process-development. The efficiency due to simulation is enhanced many folds for developing desired components by reducing the cost as well as time. This paper investigates cold forging process to be adopted to produce camshafts with a target to minimize flash as well as under filling. These two factors being major problems encountered when cold forging is to be adopted for complex shaped products. The current work is primarily concerned with the development of an optimized preform design for a V8 engine camshaft. The work involved the Solid modeling of the camshaft on AutoCAD and further analyzing the developed model through finite element analysis using Deform 3D. The analysis involved understanding of metal flow, volumetric analysis and die stresses in the forging process. The materials considered for the work-piece and the dies are AISI 8620 and AISI-H-26 respectively. The sample camshaft was taken from a standard Dodge Challenger V8 engine. 10 different cases are analyzed to find out the best possible scenario. It is fund that the stress level for the developed model was very much within the design limit of the material.

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Shao, Yong, Lin Yan, Pingyi Guo, Hongyu Yang, Fengjian Shi, and Di Feng. "A Comprehensive Study on Fitness Approximation Techniques in Shape Optimization of Aerofoil Forging Preform Tools." Metals 9, no. 6 (May 28, 2019): 617. http://dx.doi.org/10.3390/met9060617.

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In the process of complex engineering designs or optimizations, a large number of physical experiments or numerical simulations are required to evaluate certain performance qualities before a satisfactory result can be obtained. In both cases, constructing an approximate model is often necessary to provide a reliable response as an alternative to experiments or simulations. In this paper, three types of approximation models were developed and applied in a shape design of an aerofoil forging preform tool. Their modeling techniques are presented in detail. An optimal Latin hypercube technique was employed for the design of the experiment and sampling with the expected coverage of parameter space. Finite element (FE) simulations of multistep forging processes were implemented to acquire the objective function values for evaluating the forging performance. By a parametric study, the effects of design variables on objective responses and correlations were investigated for a clear insight into their functional nature. Comprehensive analyses and comparisons between different approximate models have been carried out. Finally, an optimization design of a preform tool was successfully achieved based on a particle swarm (PSO) algorithm combined with the proposed approximate model.

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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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Lee, Rong-Shean, Tei-Chen Chen, and Ming-Ching Pan. "Evaluation of the preform design of a stepped forging part by coupled thermoviscoplastic finite-element analysis and visioplasticity." Journal of Materials Processing Technology 57, no. 3-4 (February 1996): 278–87. http://dx.doi.org/10.1016/0924-0136(95)02084-5.

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Petrov, Michael A., Alexander N. Petrov, and Pavel A. Petrov. "Numerical Investigation of the Material Behaviour during Compression Tests for Samples with Rough Surfaces Represented in Different Geometry Scale Factors." Key Engineering Materials 716 (October 2016): 736–52. http://dx.doi.org/10.4028/www.scientific.net/kem.716.736.

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In modern technological operation, the original sample could be provided by so-called pre-operation or pre-forming follows prior the main operation. In such case, the surface roughness of the tool set is directly owned by the surface of the pre-formed workpiece, as less rigid body compared with the tool set. In metal forming practice there are mainly several pre-forming processes, among them roll forging, cross-wedge rolling and electro-upsetting. In any non-convenient forging operation route, where pre-forming is done by casting, powder sintering or any additive technology (e.g. SLS, EBM), the surface roughness and wellness obtained pre-formed workpiece could influence stronger on the quality of the end part after main forging operation. In order to investigate the different materials’ behaviours depends on the surface artificial roughness the finite-element analysis (FEA) was carried out for the simple compression tests, thereby the cylindrical, made from aluminium and titanium alloys, and ring specimens, made from steel, were compressed between two flat dies with modelled zero and non-zero roughness at room and elevated temperatures. The behaviour of the lubricant (fluid phase) positioned between two neighboured peaks of the roughed surface was investigated in one direction material flow test as well. The results have shown the strong pressure increase in the bottom area of the peaks, which correspond the practice case, when the fluid phase is not completely evaporated after lubrication. Further, it can course the different microstructure evolution during hot forging operation and during cold bulk forming operation, additional surface pressure can result the material hardening near to the contact zone (not investigated here). In commonly, in observed results the peaks of the roughness can be easily broken due to enormous tangential stresses, as it is well known from the fundamental investigations. Moreover, the computation of geometry scaled tools and workpieces of the ring compression and one-direction material flow tests resulted the exponential dependency against the deformation forces.

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Winiarski, Grzegorz, and Anna Dziubińska. "Analysis of a New Process of Forging a 2017A Aluminum Alloy Connecting Rod." Journal of Manufacturing Science and Engineering 143, no. 8 (March 29, 2021). http://dx.doi.org/10.1115/1.4050185.

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Abstract The paper presents the results of a theoretical analysis of a new process of hammer forging of a connecting rod and the technology currently used. In the industry at present connecting rods are forged from extruded rods. The new forging technology assumes the use of a workpiece in the form of a cast preform. For the calculations, it has been assumed that the billet material will be a Ø30 × 148 mm rod and a cast preform. Two variants of preforms have been modeled, from which products of the assumed geometry with different degree of strain are obtained. Calculations were made using the finite element method (FEM) in the Deform 3D program. The input material was 2017A aluminum alloy in the form of rods and sand cast preforms. On the basis of the conducted research, it was found that the use of cast preforms reduces material waste by about 80% in relation to the technology of forging from the bar and reduces the energy consumption of the process by about 75%. Both geometrical variants of the forging preforms ensure obtaining a forging with the assumed shape and dimensions, although forging from the forging preform with a smaller degree of strain seems to be a safer variant in terms of the possibility of cracking of the material. This is supported by the lower strain and normalized Cockcroft–Latham integral values.

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Churl Song, Min, Chester J. VanTyne, Jin Rae Cho, and Young Hoon Moon. "Optimization of Preform Design in Tadeusz Rut Forging of Heavy Crankshafts." Journal of Manufacturing Science and Engineering 139, no. 9 (July 20, 2017). http://dx.doi.org/10.1115/1.4037039.

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Tadeusz Rut (TR) forging is a widely used forging method to create heavy, solid crankshafts for marine or power-generating engines. The preform of a TR forging is forged into a crank throw by simultaneously applying both a vertical and a horizontal deformation. It is necessary to optimize the preform design, since a conventional analytical design for the preform gives various choices for the geometric variables. The purpose of the current study is to optimize the preform design in TR forging for heavy crankshafts in order to improve the dimensional accuracy of a forged shape using a limited material volume. A finite element (FE) model for TR forging was developed and validated by comparing with experimental results. Parametric FE analyses were used to evaluate the effects of the geometric variables of the preform on the final dimensions of the forged product. The geometric variables of the preform were optimized by a response-surface method (RSM) to obtain the results of parametric FE analyses. The volume allocation between the pin and the web of the preform is the dominant factor that affects the desirability of the final forged shape. A multi-objective optimization is employed to consider the mutually exclusive changes of local machining allowances of the final forged product. Optimization using a response-surface method is a useful tool to reach the large and uniform machining allowances that are required for the preform necessary for a TR forging.

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Perumal, Venkateswaran, Sivakumar Palanivelu, Siba Prasad Mookherjee, and Ajit Kumar Jindal. "Influence of Forging Process on Fatigue Properties of AISI 4140 Steel Axle Component." Journal of Engineering Materials and Technology 134, no. 1 (December 21, 2011). http://dx.doi.org/10.1115/1.4005405.

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The present paper investigates the microstructure and mechanical properties’ aspects of AISI 4140 steel front axle beams developed by roll and hot-die forging processes. Microstructure of the processed beams exhibited tempered martensite, and nonmartensitic products, such as retained austenite and ferrite at the case and core, respectively. Fatigue testing results indicate that roll forged beams have demonstrated 37% higher fatigue lives (Weibull B50 life) compared to hot-die forged beams, despite similar quasi-static tensile properties. The improved fatigue performance of the roll forged beams over hot-die forged beams is attributed to the fine, close texture and rationalized material flow in the beams processed by the roll forging process. Finite element analysis and experimental strain measurements of subject component indicate that the stress levels due to fatigue loads are well below the static yield strength and endurance limit of AISI 4140 steel; however, the notches present in the form of flash or partition lines of the forged beams have initiated the fatigue failures of the beams.

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Journal articles on the topic 'Roll-forging, Finite Element Analysis, Preforms in Forging'

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