Analytical and numerical modelling of open-die forging process for elliptical cross-section of billet

Krishna, R. Hari; Jena, D.P.

doi:10.1016/j.measurement.2018.12.023

Cited by 11 publications

(8 citation statements)

References 15 publications

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“…This is especially justified in the case when the forging has a complex shape such as that of a turbine blade, a toothed gear, a yoke, etc. [17][18][19][20][21][22][23][24][25][26]. In turn, the authors of [17] developed an experimental-numerical methodology of identifying coefficients for constitutive equations in the case of die forging on presses.…”

Section: Introductionmentioning

confidence: 99%

“…The article [18] uses FE modelling for the simulation of a process of quenching with water of a forged block made of high durability steel, in order to determine the deformation and residual stresses. In paper [19] authors propose a novel analytical solution for open-die forging for the billet of elliptical crosssection for AA6063-T7 and AA6061 alloys. In a similar manner, the FEA simulation for a closed-die forging process has been carried out and validated against experimental result.…”

Section: Introductionmentioning

confidence: 99%

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Analysis and Improvement of an Industrial Process of Hot Die Forging of an Elongated Forging Tipped with a Joggle with the Use of Numerical Simulation Results

Hawryluk¹,

Rychlik²,

Polak³

et al. 2023

Adv. Sci. Technol. Res. J.

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The article performs an analysis of a hot die forging process of producing an elongated forging ended with a joggle in a double system realized on a crank press Masey 1300 t, in open dies, in 3 operations. The thermomechanical model of the forging process considering the changes in the grain size and the forging material recrystallization was elaborated with the use of the calculation packet Qform 7. In the first place, an in-depth analysis of the currently realized forging technology was made, with a special consideration of the temperature changes in the tools as well as in the formed forging. Next, numerical modelling of the process was carried out, as a result of which the following were obtained: correct filling of the tool impressions by the deformed material, the temperature distributions for the forging and the tools, the plastic deformation distributions (considering the thermally activated phenomena), the changes in the grain size and the forging force courses. The results obtained from FEM enable a thorough analysis of the forging process, including: the effect of the deformation time and temperature on the grain size in the forging material, which was confirmed by the microstructure examination results.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Analysis and Improvement of an Industrial Process of Hot Die Forging of an Elongated Forging Tipped with a Joggle with the Use of Numerical Simulation Results

Hawryluk¹,

Rychlik²,

Polak³

et al. 2023

Adv. Sci. Technol. Res. J.

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show abstract

“…Appropriate experience in and knowledge of working with numerical calculation programs and consideration of the errors caused by the adopted simplifications in the FEM model make it a valuable tool in the analysis and improvement of current and new manufacturing technologies. Numerical modeling makes it possible to define the the flow of the material of the formed forgings and the process of cavity filling, the field of temperature distributions within the forgings and on the tools, as well as determination of the force parameters, stress and plastic deformation, and other important parameters [22][23][24]. It needs to be highlighted that the time of the material forming during forging is <0.2 s, making it very difficult to track or conduct observations/thorough analysis of the manufacturing process in such a small time -in such a case, numerical modeling is irreplaceable [25,26].…”

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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“…They showed that the new forging schemes provided a uniform distribution of grain size in the obtained billets. Krishna and Jena [13] proposed an analytical solution, based on the slab method, for open die forging of elliptical cross-section billets. Banaszek et al [14] presented the results of numerical modeling of the forging process of magnesium alloy ingots on a hydraulic press with the use of flat and shaped dies.…”

Section: Introductionmentioning

confidence: 99%

Limit analysis of plane strain compression of cylindrical billets between flat dies

Bina

Haghighat

2021

Int J Adv Manuf Technol

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Plane strain compression of cylindrical billets with flat dies has been studied in this paper. A deformation model has been proposed and the dimensions of the deformed billet cross-section for a given press stroke have been determined. To analyze the process, two types of theoretical approaches, i.e., the upper bound technique and the slab method of analysis have been applied and the required forming load has been estimated. Analytical results of billet cross-section deformed geometry and compression load have been compared with the finite element data obtained by the DEFORM 2D ver11.0 finite element package. It is shown that there is a satisfactory agreement between the theoretical predictions and the FE simulation data. The solution can be used in industrial applications for evaluating the required press load to deform the long circular cross-section billets, which is essential for selecting the forming machine with enough capacity.

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Analytical and numerical modelling of open-die forging process for elliptical cross-section of billet

Cited by 11 publications

References 15 publications

Analysis and Improvement of an Industrial Process of Hot Die Forging of an Elongated Forging Tipped with a Joggle with the Use of Numerical Simulation Results

Analysis and Improvement of an Industrial Process of Hot Die Forging of an Elongated Forging Tipped with a Joggle with the Use of Numerical Simulation Results

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

Limit analysis of plane strain compression of cylindrical billets between flat dies

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