Closed Die Forging Geometrical Parameters Optimization for Al-MMC

Abstract

Demand for lighter and stiffer products has been increasing in the last few years especially in automobile manufacturing. The closed die forging process of Metal Matrix Material (MMC) is presented as possible solution, since it produces parts with good mechanical properties and lighter weight. A computational modeling of closed die forging process using finite element method and optimization techniques makes the design optimization faster and more efficient, decreasing the use of conventional trial and error methods. In this study, the application of commercial finite element software (ANSYS) has been used to model cold closed die forging process. The model has been developed using ANSYS Parametric Design Language (APDL) to simulate a single stage axisymmetry closed die forging process for H cross sectional shape. The material used is AlMgSi matrix with 15% SiC particles. Its flow curve and fractural strain are obtained from the literature. ANSYS Optimizer is used to obtain the maximum height in which the material can flow in the rib by changing Design Variables (DV) and State Variables (SV). Normally design variables are geometrical parameters such as, rib height to width ratio, web height to rib height ratio, fillet radii, draft angle and billet radius. State Variables (SV) are some parameters that depend on the design variables such as, the equivalent strain which must be below the fracture strain of the MMC material, and an acceptable contact gap (within the allowable tolerances range). Optimization method called Sub-Problem Approximation Method was used to find out the optimal design set. The technique used in this study can be used for newly developed materials to investigate its forgeability for much complicated shapes in closed die forging process.

Structural-topological synthesis of space mechanisms with rods and wheels

“…This results in a "forced" drive balancing from the transmission, which makes the operation of the assembly to be correct but rigid and with mechanical shocks. Such balancing is not possible when the actuators directly actuate the elements of the kinematic chain without using mechanical reducers PETRESCU, 1985;1989;ANTONESCU et al, 1985a;1985b;1986;1987;1988;1994;1997;2001;ATEFI et al, 2008;Avaei et al, 2008;AVERSA et al, 2017a;2016d;2016e;2016f;2016g;2016h;2016i;2016j;2016k;2016l;2016m;2016n;2016o;AZAGA;OTHMAN, 2008;CAO et al, 2013;DONG et al, 2013;EL-TOUS, 2008;COMANESCU, 2010;FRANKLIN, 1930;HE et al, 2013;JOLGAF et al, 2008;KANNAPPAN et al, 2008;LEE, 2013;LIN et al, 2013;LIU et al, 2013;MIRSAYAR et al, 2017;NG et al, 2008;PADULA;PERDEREAU;PANNIRSELVAM, 2008;2013;…”

Structural-Topological Synthesis of Space Mechanisms With Rods and Wheels

“…This results in a "forced" drive balancing from the transmission, which makes the operation of the assembly to be correct but rigid and with mechanical shocks. Such balancing is not possible when the actuators directly actuate the elements of the kinematic chain without using mechanical reducers (ANTONESCU; PETRESCU, 1985;1989;ANTONESCU et al, 1985a;1985b;1986;1987;1988;1994;1997;2000a;2000b;2001;ATEFI et al, 2008;Avaei et al, 2008;AVERSA et al, 2017a;2016d;2016e;2016f;2016g;2016h;2016i;2016j;2016k;2016l;2016m;2016n;2016o;AZAGA;OTHMAN, 2008;CAO et al, 2013;DONG et al, 2013;EL-TOUS, 2008;COMANESCU, 2010;FRANKLIN, 1930;HE et al, 2013;JOLGAF et al, 2008;KANNAPPAN et al, 2008;LEE, 2013;LIN et al, 2013;LIU et al, 2013;MIRSAYAR et al, 2017;NG et al, 2008;PADULA;PERDEREAU;PANNIRSELVAM, 2008;…”

A Preliminary Study on the Optimal Shape Design of the Axisymmetric Forging Component Using Equivalent Static Loads

“…예비성형공정이 포함된 다단 계 공정과 그렇지 않은 단일공정에서의 단조품 성 형 결과를 비교한 것이다. (3,4) 적절하지 않은 예비성형체는 소재의 불충진과 플래시 등의 성형결함을 발생시킨다. 플래시의 발 생은 플래시 제거를 위한 추가공정이 필요하고 이 로 인한 재료의 손실이 발생하게 된다.…”

“…또한 소재 의 불충진은 제품의 품질 저하의 원인이 되며 부 품으로서 부적합하여 사용하지 못한다. (1)(2)(3)(4) 이러한 이유로, 최종가공에 적합한 예비성형체의 형상 설 계가 요구되며 관련 연구가 활발하게 진행 중이다.…”