A Fully Coupled Thermomechanical Damage Analysis of Hot Closed Die Forging Using Finite Element Modeling

Nytra, Michal; Kubík, Petr; Petruška, Jindřich; Šebek, František

doi:10.1007/s11665-020-05252-4

Cited by 6 publications

(4 citation statements)

References 37 publications

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“…For example, a previous study [37] has proposed an experimental numerical methodology for identifying the parameters of the constitutive laws applied for the hot forging processes realized in industrial presses. An another work [38] presents the numerical simulations referring to the whole production process, except for the machining treatment, of a front-toothed wheel forging for the rear gear of the motorcar gear box; similarly, another study [39] uses numerical modeling for the fast forging of railway axles made of 25CrMo4 steel by the application of Forge software (Transvalor, Sophia Antipolis cedex France), together with analysis of the evolution of the grain size during a multistage forging process at high speed. A 3D model of finite elements has also been used [40] to forecast the residual stresses and the deformations in the simulation of the water hardening of a large forged component made of highstrength steel.…”

Section: Introductionmentioning

confidence: 99%

Analysis of the production process of the forked forging used in the excavator drive system in order to improve the currently implemented technology by the use of numerical modeling

Hawryluk

Rychlik²,

Ziemba

et al. 2021

Materials Science-Poland

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The study concerns a comprehensive analysis of a multistage hot-die forging on hammers, in order to produce a yoke-type forging, used as a component of excavator power transmission systems. The investigations were conducted with the aim to analyze and identify the sensitive areas in the process and then improve the currently implemented forging technology by using finite element (FE) simulation. QuantorForm (the developer of the QForm program) has developed a thermomechanical numerical model for the production of forked forging. The software Computer-Aided Three-Dimensional Interactive Application (CATIA) was used to develop and build Computer-Aided Design (CAD) models of forging tools. As a result of the numerical simulations, the plastic deformations and temperature distributions for the forgings and tools were obtained, and the force courses during the forging process were analyzed. The obtained results enabled a thorough analysis of the forging process, including identification of potential forging defects (laps) as well as those tool areas that are the most loaded and exposed to damage. On this basis, changes were implemented in the production process, which allowed for the improvement of the currently implemented technology and obtaining the corrected forgings.

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Section: Introductionmentioning

confidence: 99%

Analysis of the production process of the forked forging used in the excavator drive system in order to improve the currently implemented technology by the use of numerical modeling

Hawryluk

Rychlik²,

Ziemba

et al. 2021

Materials Science-Poland

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“…Forging technology involves a large number of experimental variables (for example, temperature, friction coefficient, and deformation rate), so the optimization process of the product requires a high experiment cost and long operation time. To reduce the investigation costs, improvements can be made by preforming the product and combining it with an FEM simulation to reduce the number of experiments [ 12 , 13 , 14 ]. Therefore, Jiang et al [ 15 ] utilized FEM to simulate and study the causes of streamlined defects in the forming process of bearing rings to mend forging defects.…”

Section: Introductionmentioning

confidence: 99%

A Comparison and Analysis of Three Methods of Aluminum Crown Forgings in Processing Optimization

Chen

Shih

et al. 2022

Materials

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In this study, three parameter optimization methods and two designs of experiments (DOE) were used for the optimization of three major design parameters ((bill diameter (D), billet length (L), and barrier wall design (BWD)) in crown forging to improve the formability of aluminum workpiece for shock absorbers. The first optimization method is the response surface method (RSM) combined with Box–Behnken’s experimental design to establish fifteen (15) sets of parameter combinations for research. The second one is the main effects plot method (MEP). The third one is the multiobjective optimization method combined with Taguchi’s experimental design method, which designed nine (9) parameter combinations and conducted research and analysis through grey relational analysis (GRA). Initially, a new type of forging die and billet in the controlled deformation zone (CDZ) was established by CAD (computer-aided design) modeling and the finite element method (FEM) for model simulation. Then, this investigation showed that the optimal parameter conditions obtained by these three optimization approaches (RSM, MEP, and multiobjective optimization) are consistent, with the same results. The best optimization parameters are the dimension of the billet ((D: 40 mm, the length of the billet (L): 205 mm, and the design of the barrier wall (BWD): 22 mm)). The results indicate that the optimization methods used in this research all have a high degree of accuracy. According to the research results of grey relational analysis (GRA), the size of the barrier wall design (BWD) in the controllable deformation zone (CDZ) has the greatest influence on the improvement of the preforming die, indicating that it is an important factor to increase the filling rate of aluminum crown forgings. At the end, the optimized parameters are verified by FEM simulation analysis and actual production validation as well as grain streamline distribution, processing map, and microstructure analysis on crown forgings. The novelty of this work is that it provides a novel preforming die through the mutual verification of different optimization methods to solve a typical problem such as material underfill.

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“…First, a transient temperature field of the built part is simulated, and the temperature results are then used to perform the mechanical analysis. This method is computationally less expensive compared to fully coupled analysis in which the temperature and displacement degrees of freedom are solved simultaneously and updated for each time increment [13]. An indirect coupling approach has been successfully used to investigate the AM process to predict residual stress formations and geometric deformations to good accuracies [14][15][16][17][18][19].…”

Section: Introductionmentioning

confidence: 99%

Numerical Investigation on the Effect of Residual Stresses on the Effective Mechanical Properties of 3D-Printed TPMS Lattices

Ahmed

Barsoum

Al‐Rub

2022

Metals

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The layer-by-layer process of additive manufacturing (AM) is known to give rise to high thermal gradients in the built body resulting in the accumulation of high residual stresses. In the current study, a numerical investigation is conducted on the effect of residual stresses on the mechanical properties of IN718 triply periodic minimal surface (TPMS) lattices fabricated using the selective laser melting (SLM) process for different relative densities. The AM simulation of four different sheet- and ligament-based TPMS topologies, namely, Schwarz Primitive, Schoen Gyroid, Schoen IWP-S, and IWP-L, are performed using a sequentially coupled thermomechanical finite element model to evaluate the thermal histories and residual stress evolution throughout the SLM process. The finite element results are utilized to obtain the effective mechanical properties, such as elastic modulus, yield strength, and specific energy absorption (SEA), of the TPMS lattices while accounting for the residual stress field arising from the SLM process. The mechanical properties are correlated to relative density using the Gibson–Ashby power laws and reveal that the effect of the residual stresses on the elastic modulus of the as-built TPMS samples can be significant, especially for the Schwarz Primitive and Schoen-IWP-L TPMS topologies, when compared to the results without accounting for residual stresses. However, the effect of the residual stresses is less significant on yield strength and SEA of the TPMS samples. The work demonstrates a methodology for numerical simulations of the SLM process to quantify the influence of inherited residual stresses on the effective mechanical properties of complex TPMS topologies.

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A Fully Coupled Thermomechanical Damage Analysis of Hot Closed Die Forging Using Finite Element Modeling

Cited by 6 publications

References 37 publications

Analysis of the production process of the forked forging used in the excavator drive system in order to improve the currently implemented technology by the use of numerical modeling

Analysis of the production process of the forked forging used in the excavator drive system in order to improve the currently implemented technology by the use of numerical modeling

A Comparison and Analysis of Three Methods of Aluminum Crown Forgings in Processing Optimization

Numerical Investigation on the Effect of Residual Stresses on the Effective Mechanical Properties of 3D-Printed TPMS Lattices

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