Casting Manufacturing of Cylindrical Preforms Made of Low Alloy Steels

Demler, Eugen; Götze, Stanislav; Herbst, Sebastian; Nürnberger, Florian; Maier, Hans Jürgen; Ursinus, Jonathan; Büdenbender, Christoph; Behrens, Bernd‐Arno

doi:10.1016/j.promfg.2020.04.333

Cited by 4 publications

(5 citation statements)

References 6 publications

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“…This translates into improved tensile and functional properties when compared with products manufactured by the mechanical processing of castings [ 39 , 40 , 41 , 42 , 43 , 44 ]; Possibility of forming connecting rods from less ductile alloys possessing better tensile properties. The use of a shaped, cast preform without metal forming will have a positive effect on the flow kinematics and deformability of the material during forging [ 45 , 46 , 47 , 48 ]; Ecofriendliness of the novel process. It stems from a more eco-friendly production method, i.e., lower waste volume in comparison to the connecting rod manufacturing method in current employment.…”

Section: Discussionmentioning

confidence: 99%

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The New Technology of Die Forging of Automotive Connecting Rods from EN AB-71100 Aluminium Alloy Cast Preforms

Dziubińska

2023

Materials

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This article presents a new technology for forming automotive connecting rod forgings by means of die forging from cast performs from EN AB-71100 (EN AB-AlZn10Si8Mg) aluminum alloy. A premise was made that the production process would be carried out on forging presses. The process of forming connecting rod forgings was analyzed considering different deformation rates related to the type of machine used: a crank press and a screw press. The billet in the form of in-house designed, shaped preforms cast into sand molds with two variants of geometry was used in the process. The numerical analysis of the new process was carried out on the basis of the finite element method using Deform 3D, the simulation software for metal forming. The simulations were conducted in the spatial deformation conditions, considering the full thermomechanical analysis. Based on the simulations, certain important findings concerning the novel process were acquired, including the distribution of stress, deformation, temperatures, cracking criterion and energy parameters. The results of numerical tests confirmed the possibility of producing defect-free forgings of connecting rods from EN AB-71100 aluminum alloy on forging presses by means of the proposed technology. The proposed process of forging using crank and screw presses was verified in the course of tests conducted in industrial conditions. The properly formed connecting rod forgings were subjected to quality tests in terms of their structure and mechanical properties.

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Section: Discussionmentioning

confidence: 99%

“…Possibility of forming connecting rods from less ductile alloys possessing better tensile properties. The use of a shaped, cast preform without metal forming will have a positive effect on the flow kinematics and deformability of the material during forging [ 45 , 46 , 47 , 48 ];…”

Section: Discussionmentioning

confidence: 99%

The New Technology of Die Forging of Automotive Connecting Rods from EN AB-71100 Aluminium Alloy Cast Preforms

Dziubińska

2023

Materials

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“…The forging technology allows for the final forming of the forgings and the improvement of its strength parameters. In specialist literature the descriptions of such production can be found, for example, of flanges [15], suspension arms [16] or pistons [17] with the use of various types of material, such as magnesium alloys AZ70 [18] or steel [19,20].…”

Section: Introductionmentioning

confidence: 99%

Numerical Analysis of the New Forming Process of the Aircraft Bracket Forging Made of AZ91 Alloy at Different Rates of Deformation

Dziubińska

Surdacki

2022

Teh. vjesn.

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The article presents the results of numerical simulations of the new forging process of the aircraft bracket forging at different deformation rates related to the type of machine used: a hydraulic press, a screw press and a drop forging hammer. The billet of shaped preforms from AZ91 alloy with two different geometries was used for the process. It was assumed that forging a bracket from an unformed, shaped preform will have a positive effect on the kinematics of the flow and on the deformation capability of AZ91 magnesium alloy, and will reduce the number of operations necessary to obtain the correct item. The numerical analysis of the new process was carried out with FEM, using the software Deform 3D. Based on the simulation, the important information about the process was obtained, that is the distribution of stress, deformation, temperatures, cracking and force parameters. The obtained results of numerical tests confirmed the possibility of producing the correct aircraft brackets forgings from AZ91 magnesium alloys with the proposed technology.

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“…In pursuit of a robust mold design, it allows a shift from the conventional trial-and-error approach to a modern proof-of-concept approach which makes the process faster, more efficient and less expensive [2]. The simulation-based optimization is a relatively new idea for developing a robust mold design [3][4][5][6][7]. Demler et al used casting simulation software to determine suitable casting parameters and to predict porosity in components of a drive train made of low alloy steel [4].…”

Section: Introductionmentioning

confidence: 99%

“…The simulation-based optimization is a relatively new idea for developing a robust mold design [3][4][5][6][7]. Demler et al used casting simulation software to determine suitable casting parameters and to predict porosity in components of a drive train made of low alloy steel [4]. Simulation results suggested a suitable casting temperature of 1680 • C together with a casting time of 10 s. The exact locations of feeders are also identified using simulations to ensure proper filling of the molten metal in critical areas of the casting cavity.…”

Section: Introductionmentioning

confidence: 99%

Fatigue Life and Reliability of Steel Castings through Integrated Simulations and Experiments

Khan

Sheikh

Gasem

et al. 2022

Metals

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The quality and performance of steel castings is always a concern due to porosities formed during solidification of the melt. Nowadays, computational tools are playing a pivotal role in analyzing such defects, followed by their minimization through mold design optimization. Even if the castings are produced with defects in a permissible range, it is important to examine their service life and performance with those defects in a virtual domain using simulation software. This paper aims to develop a methodology with a similar idea of simulation-based optimization of mold design and predictions of life and reliability of components manufactured with minimized casting defects, especially porosities. The cast parts are standard fatigue specimens which are produced through an optimized multi-cavity mold. X-ray imaging is done to determine the soundness of cast parts. Experimental work includes load-controlled fatigue testing under fully reversed condition. The fatigue life of specimens is also simulated and compared with the experimental results. The classical strength-stress model is used to determine the reliability of cast parts through which a safe-load induced stress of steel castings is determined. Finally, probability distributions are fit to the reliability results to develop the reliability models. It is found that porosities can be minimized significantly in the mold design phase using casting simulations. Nevertheless, some porosities are bound to exist, which must be included in realistic estimation of fatigue life and reliability of cast parts.

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Casting Manufacturing of Cylindrical Preforms Made of Low Alloy Steels

Cited by 4 publications

References 6 publications

The New Technology of Die Forging of Automotive Connecting Rods from EN AB-71100 Aluminium Alloy Cast Preforms

The New Technology of Die Forging of Automotive Connecting Rods from EN AB-71100 Aluminium Alloy Cast Preforms

Numerical Analysis of the New Forming Process of the Aircraft Bracket Forging Made of AZ91 Alloy at Different Rates of Deformation

Fatigue Life and Reliability of Steel Castings through Integrated Simulations and Experiments

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