Analysis of the impact of forging and trimming tools wear on the dimension-shape precision of forgings obtained in the process of manufacturing components for the automotive industry

Hawryluk, Marek; Kondracki, Piotr; Krawczyk, J.; Rychlik, Marcin; Ziemba, Jacek

doi:10.17531/ein.2019.3.14

Cited by 6 publications

(4 citation statements)

References 32 publications

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“…Spatial (3D) scanning can be realized by means of many different techniques, but it should be remembered that each of them has strengths and limitations. In hot-die-forging processes, measurement by non-contact scanning is used for two groups of objects: measurements for the evaluation of the forging equipment and measurements of the key geometric features of the forgings, as well as quality control of the resulting final detail [ 49 , 50 ].…”

Section: Methodsmentioning

confidence: 99%

Possibilities of Measuring and Detecting Defects of Forged Parts in Die Hot-Forging Processes

Hawryluk,

Polak,

Rychlik

et al. 2023

Materials

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This paper presents research results in the field of industrial die forging, mostly related to the use of advanced measuring techniques and tools, numerical simulations, and other IT tools and methods for a geometrical analysis of the forged items as well as detection of forging flaws and their prevention, and optimization of the hot-forging processes. The results of the conducted investigations were divided into three main areas. The first area refers to the application of, e.g., optical scanners and programs related to their operation, data analysis, including the construction of virtual gauges, measurements of selected geometrical features of both the manufactured forgings and their physical and virtual models, as well as an analysis of the durability of the forging tools based on the proprietary reverse scanning method. The second area presents the results of measurements and analyses performed with the use of finite element modeling and by means of some special functions in the calculation packages, such as contact, flow lines, trap, or fold, for the detection of forging defects and an analysis of the force parameters. In turn, the third area presents a combination of different methods of measurement and analysis, both FEM and scanning, as well as other IT methods (physical modeling, image analysis, etc.) for the analysis of the geometry and defects of the forgings. The presented results point to the great potential of these types of tools and techniques in forging industry applications as they significantly shorten the time and increase the accuracy of the measurement, as well as providing a lot of valuable information, physical variables, and technological parameters that are difficult or impossible to determine either analytically or through experimental means. The use and development of these techniques and methods are fully justified, both in the aspect of science and the increased effectiveness and efficiency of production.

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Section: Methodsmentioning

confidence: 99%

Possibilities of Measuring and Detecting Defects of Forged Parts in Die Hot-Forging Processes

Hawryluk,

Polak,

Rychlik

et al. 2023

Materials

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“…The model of the material, steel C45, was collected from the Forge “FPD Base 1.3” database. Detailed information related to additional conditions can be found in [ 52 ].…”

Section: Test Subject Scientific Problem and Research Methodologymentioning

confidence: 99%

Application of 3D Scanning as an Indirect Method to Analyze and Eliminate Errors on the Manufactured Yoke-Type Forgings Forged in SMED Device on Modernized Crank Press

Ziemba

Hawryluk

Rychlik³

2020

Materials

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This article proposes an indirect measurement method based on a dimensional and shape analysis of forgings for the evaluation of the manufacture and the proper operation of the key elements of the crank press, in which after modernization, a quick tool assembly based on SMED (Single Minute Exchange of Die) was implemented. As a result of the introduced changes aiming at improving the forging aggregate and increasing the production efficiency, errors were observed on the manufactured products-forgings in the form of twists and joggles. In order to solve the problem, a lot of advanced methods was used, including: dynamic system of deformation analysis, numerical modeling and as well as dimensional and shape analysis by 3d scanning. Despite the above, this approach (classic way) did not solve the problem. A proprietary method with the use of 3D reverse scanning was proposed, which allows to solve the problem of forgings errors. Based on the measurement results and analyses for a few variants of production cycles, the necessary changes were obtained, making it possible to minimize the errors and obtain proper products in respect of geometry and quality.

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“…The main issue is the degradation of the quality of forged parts, i.e., occurrence of various forging defects, poor dimensional and shape accuracy of forged parts, etc. [6,7]. The short tool lifetime has also important economic effects, as the tool itself may account for even 8 to 15% of the total production costs, or even more in case of an unexpected tool's failure [4].…”

Section: Introductionmentioning

confidence: 99%

The Influence of the Hot Working Tool Steel Substrate Material on the Element Distribution, Microstructure and Hardness of Gas Metal Arc Welding Hardfaced Layers

Lachowicz,

Sokołowski,

Kaszuba

2024

Adv. Sci. Technol. Res. J.

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The paper presents the results of gas metal arc welding (GMAW) hardfacing testing performed on three grades of hot working tool steels, namely: 55NiCrMoV7, X37CrMoV5-1 and modified X38CrMoV5-3 grade. Metallographic investigations, mainly microstructural ones, were carried out and hardness profiles were analyzed. The chemical composition was investigated in each individual layer of the hardfaced deposits and the substrate material, in order to obtain a profile representation. The obtained results of profilometric evaluation of the chemical composition showed clear differences in the content of basic and alloying elements in the subsequent weld layers. The diversity of the chemical composition of the substrate material caused that the uniform chemical composition for all tested materials was achieved only in the third, upper weld layer. Despite the variable content of alloying elements and carbon, as well as slight differences in microstructure occurring for individual weld layers, a substantially stable and high hardness was maintained over the entire cross-section of the obtained hardfaced coatings. In the area of the heat-affected zone (HAZ), a decrease in hardness was observed, which is associated with the decomposition of the high-temperature tempered martensite and the spheroidization of the microstructure.

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Analysis of the impact of forging and trimming tools wear on the dimension-shape precision of forgings obtained in the process of manufacturing components for the automotive industry

Cited by 6 publications

References 32 publications

Possibilities of Measuring and Detecting Defects of Forged Parts in Die Hot-Forging Processes

Possibilities of Measuring and Detecting Defects of Forged Parts in Die Hot-Forging Processes

Application of 3D Scanning as an Indirect Method to Analyze and Eliminate Errors on the Manufactured Yoke-Type Forgings Forged in SMED Device on Modernized Crank Press

The Influence of the Hot Working Tool Steel Substrate Material on the Element Distribution, Microstructure and Hardness of Gas Metal Arc Welding Hardfaced Layers

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