Fully Coupled Finite Element Analysis of an Automatic Multi-Stage Cold Forging Process

Byun, Jong Bok; Lee, Hyun Joon; Park, Jong Bok; Seo, Il Dong; Joun, Man Soo

doi:10.4028/www.scientific.net/ssp.311.88

Cited by 8 publications

(5 citation statements)

References 18 publications

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“…[6] However, the advances in flow characterization have been relatively slow, even though a lot of research works have been made keeping pace with the advances in material test equipment and technology. One of the important issues in automatic multistage cold forging [5][6][7][8] is the flow stress at the larger strain, for example, at least 3.0. The matter related to this issue involves the acquisition of such flow curve and its mathematical description.…”

Section: Introductionmentioning

confidence: 99%

General Blending Approach of Fundamental Cold Flow Models for an Almost Complete Cold Flow Model in Terms of Tensile Test

Byun

Jee

Lee³

et al. 2023

steel research int.

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The importance of two major issues in obtaining an almost complete cold flow model (ACCFM) from a tensile test, that is, the necking conditions (including the Considère condition and tensile strength) and several selected representative flow points in both pre‐ and postnecking strain hardening regions, is emphasized. It is shown using the AISI 1010 steel for automatic multistage cold forging (AISI 1010 equivalent) that all the traditional fundamental flow models (FFMs) such as the Ludwik, Voce, Hollomon, and Swift models cannot simultaneously satisfy the two major issues. A general blended flow model (BFM) is proposed, which is a linear combination of known basis blending functions satisfying the necking conditions. The number of basis blending functions is unconstrained. The constants of the linear combination, called blending coefficients, are calculated by a set of linear equations to meet the selected representative flow points. Numerous combinations of basis flow functions are tried. It has been shown that there is no interpolation case among all the obtained BFMs but that there are a few ACCFM‐acceptable cases among them, which are based on the extrapolation of the basis blending functions.

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Section: Introductionmentioning

confidence: 99%

General Blending Approach of Fundamental Cold Flow Models for an Almost Complete Cold Flow Model in Terms of Tensile Test

Byun

Jee

Lee³

et al. 2023

steel research int.

Self Cite

View full text Add to dashboard Cite

show abstract

“…However, it can be meaningful only when the flow curves are normal, i.e., monotonically increasing, such as those of cold forgeable carbon steels [4,41,42]. The conventional approaches of obtaining flow stress behaviors at high strain and room temperature cannot be applied to some ultra-high strength steels [43,44], stainless steels [8,45,46], special heat-treated steels [47], aluminum alloys [48,49], new materials [50,51], etc.…”

Section: Introductionmentioning

confidence: 99%

A Review of Flow Characterization of Metallic Materials in the Cold Forming Temperature Range and Its Major Issues

et al. 2022

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We focus on the importance of accurately describing the flow behaviors of metallic materials to be cold formed; we refer to several valuable examples. We review the typical experimental methods by which flow curves are obtained, in addition to several combined experimental-numerical methods. The characteristics of four fundamental flow models including the Ludwik, Voce, Hollomon, and Swift models are explored in detail. We classify all flow models in the literature into three groups, including the Ludwik and Voce families, and blends thereof. We review the experimental and numerical methods used to optimize the flow curves. Representative flow models are compared via tensile testing, with a focus on the necking point and pre- or post-necking strain hardening. Several closed-form function models employed for the non-isothermal analyses of cold metal forming are also examined. The traditional bilinear C-m model and derivatives thereof are used to describe the complicated flow behaviors of metallic materials at cold forming temperatures, particularly in terms of their applications to metal forming simulations and process optimization.

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“…CAE-системы на основе метода конечных элементов (КЭ) находят применение при проектировании и оптимизации существующих технологических процессов металлообработки, изучении контактного взаимодействия и характеристик процесса трения [7][8][9], анализе температурного поля и напряженного состояния инструмента при различных видах механической обработки, например при фрезеровании [10; 11] или штамповке [12]. Использование КЭ-моделирования при анализе процессов металлообработки достаточно продуктивно и позволяет не только определить оптимальные параметры процесса резания и конструкций режущего инструмента [8], но и прогнозировать износостойкость материалов в зависимости от условий эксплуатации [9].…”

Section: Introductionunclassified

Optimal Scheme of Laser Hardening of a Tool Wedge Tip

Yaresko¹,

Balakirov²

2021

FMT

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Laser heat treatment is one of the effective methods to improve the operational characteristics of metal-cutting tools. In the practice of laser hardening, there are several methods to select treatment mode: experimental, calculated, and according to reference data. The finite element method is promising for estimating the treatment zone parameters, and its application is the most in-demand for calculating the temperature field of a geometrically complex tool. When organizing the hardening process, the selection and setting of processing modes for the cutting wedge tip are the most difficult. In this regard, the solution for the multifactorial problem of optimizing the hardening scheme of an area near the tool tip is relevant when designing and automating the process of blade tool laser hardening. Using the finite element method in the ANSYS Workbench software, the authors carried out the numerical experiments to optimize the laser hardening scheme of the tool cutting wedge tip on the example of an instrument with a wedge angle equal to 60°. The paper considers three variants of the hardening scheme. The first variant is the implementation of multiple processing of an area adjacent to the tool tip. The second one consists of alternate movement of laser treatment spots along the cutting edges within the tool tip area. According to the third variant, the treatment spots were sequentially located along the bisector of an angle at the tool tip. The study showed that, according to the maximum depth criterion, an optimal hardening scheme is a scheme, which consists of alternate movement of laser treatment spots along the cutting edges in the tool tip area. In this case, the hardening zone characteristics are ensured that exceed similar values describing the hardening zone for other laser treatment options for the tool cutting wedge tip.

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Fully Coupled Finite Element Analysis of an Automatic Multi-Stage Cold Forging Process

Cited by 8 publications

References 18 publications

General Blending Approach of Fundamental Cold Flow Models for an Almost Complete Cold Flow Model in Terms of Tensile Test

General Blending Approach of Fundamental Cold Flow Models for an Almost Complete Cold Flow Model in Terms of Tensile Test

A Review of Flow Characterization of Metallic Materials in the Cold Forming Temperature Range and Its Major Issues

Optimal Scheme of Laser Hardening of a Tool Wedge Tip

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