Forging of Ingots Without Hot Tops

Int J Adv Manuf Technol

Markova

et al. 2015

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A new method of plate forging with V-shaped dies is proposed. The deformation state of a metal workpiece during forging has been investigated. The proposed method of forging increases the uniformity of the strain distribution with a high level of strain in the workpiece. The values of angles for V-shaped dies range from 120°to 140°. This range of die angles is the most rational from the standpoint of strain distribution uniformity and maximum widening. V-shaped die usage for plate forging leads to an increase in widening coefficient of 35 % in comparison with forging with flat dies. This forging technique provides the possibility of eliminating the operation of billet upsetting during plate forging. V-shaped die usage for plate forging also results in a decrease in deformation load in comparison with flat die forging. The scheme of plate forging by V-shaped dies results in the formation of an irregular compression state in the axial zone. It leads to the closing of defects during forging. The new technology of plate forging with V-shaped dies was tested under industrial conditions. The forged piece has satisfied the requirements of the customer's technical criteria. The ultrasonic check results have shown that the application of the proposed technology provides an increase in metal continuity within the central zone of the forged piece. The experimentally derived forging results have confirmed that upsetting operations can be eliminated, and as a result, energy expenditures and the overall cycle time of the forging operation have been reduced by 15 %.

Section: Literature Review the State Of The Artmentioning

confidence: 99%

Section: Literature Review the State Of The Artmentioning

confidence: 99%

Development of a new process for forging plates using intensive plastic deformation

Марков

Int J Adv Manuf Technol

Markova

et al. 2015

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“…The upsetting operation is the main forging process for producing large discs from ingots [23][24][25]. The upsetting operation has been carefully studied in recent research [24,[26][27][28] for identification of effective quality control parameters for the operation.…”

Section: Introductionmentioning

confidence: 99%

New schemes of forging plates, shafts, and discs

Zhbankov

Int J Adv Manuf Technol

Aliievа

2015

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This paper presents the various ways of forging large forged pieces such as shafts, plates, and discs. A finite element method was used to simulate open die forging processes such as forging by flat dies with a slant, forging by staged dies, and upsetting of profiled workpiece. The parameters of the stress strain state of the billet in these processes were determined, along with the rational parameters for forging plates by flat dies with slant such as tool size and mechanical modes. The optimal die step dimension and mechanical regime for forging shafts by staged tools was determined. Also, the rational geometric parameters of the workpiece for forging discs by upsetting were determined. For these forging schemes, a simulation was done of the microstructure evolution in forgings obtained by traditional technology and new proposed technology. The paper shows the advantages of new forging schemes which provide a uniform distribution of grain size in the obtained billets.

“…For FEM simulation the code QForm 2D (license DSEA N U1221, [28][29][30][31]) has been applied. As the first approach the frictionless plastic flow of copper grade M1 workpieces HAB-GCD (Fig.…”

Section: Finite Element Simulation Of Plastic Flowmentioning

confidence: 99%

“…1c and Fig. 2) have applications to such metal forming processes as die forging [30][31], forged pieces forging, cold multistage forming [17][18]20], sheet-metal forming, punching, backward extrusion [10-11, 14, 19, 21] and improved SPD techniques [3][4]22].…”

Section: Introductionmentioning

confidence: 99%

Effect of 2θ-Punch Shape on Material Waste during ECAE through a 2θ-Die

Materials and Manufacturing Processes

Tarasov

Zhbankov

et al. 2014

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This article is focused on the improvement of metal forming die tooling for Equal Channel Angular Extrusion (ECAE) processes through non-rectangular 2θ-dies of classical Segal geometry. The technological appropriateness of work piece deformation through 2θ-dies using inclined oblique 2θ-punches has been evaluated with an introduction of physical simulation techniques. It has been shown experimentally that for