Investigation of influencing factors on friction during ring test in hot forging using FEM simulation

Sethy, Ritanjali; Galdos, Lander; Mendiguren, Joseba; Argandoña, Eneko Sáenz de

doi:10.1063/1.4963528

Cited by 5 publications

(1 citation statement)

References 11 publications

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“…This friction law has been commonly adopted for the simulation of forging processes. It has namely been shown that it gives appropriate results when describing these operations under high temperatures [47]. This law is adopted in this study.…”

Section: Numerical Implementationmentioning

confidence: 99%

Study of the slant fracture in solid and hollow cylinders: Experimental analysis and numerical prediction

chabane

Aguechari

Ouali

2022

Frattura Ed Integrità Strutturale

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This paper is devoted to the numerical and experimental study of ductile fracture in bulk metal forming of the 2017A-T4 aluminum alloy. From an experimental standpoint, the ductile fracture of the 2017A-T4 aluminum alloy is investigated under compressive load. Two cross-sections of solid and hollow specimens are considered. The mechanical behavior and the microstructure of the 2017A-T4 aluminum alloy were characterized. It is found that the well-known barrel shape is obtained when a compressive load is applied. Analyses of fracture topographies show a ductile fracture with dimples under tension and coexistence of ductile fracture with dimples and slant under compression. The classical physically-based Gurson-Tvergaard-Needleman (GTN) model and its extension to incorporate shear mechanisms to predict failure at low-stress triaxiality are considered. These two models have been extended to take into account the thermal heating effect induced by the mechanical dissipation within the material during the metal forming process. The two models have been implemented into the finite element code Abaqus/Explicit using a Vectorized User MATerial (VUMAT) subroutine. Numerical simulations of the forging process made for hollow and solid cylindrical specimens show good agreement with experimental results. In contrast with the GTN model, the modified GTN model incorporating shear mechanisms can capture the final material failure.

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Section: Numerical Implementationmentioning

confidence: 99%

Study of the slant fracture in solid and hollow cylinders: Experimental analysis and numerical prediction

chabane

Aguechari

Ouali

2022

Frattura Ed Integrità Strutturale

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Characterization of the heat transfer coefficient at near solidus forming condition using columnar pressing test

Sajjad,

Agirre,

Plata

et al. 2024

Int J Adv Manuf Technol

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This study addresses the significant gap in the literature regarding the heat transfer coefficient (HTC) under near-solidus forming (NSF) conditions, where materials are shaped close to their solidus state, presenting complex behaviour compared to traditional hot forming processes. Despite the pivotal role of heat transfer in developing a reliable material model for the digital twin (DT), limited data exist particularly regarding HTC characterization at NSF. Additionally, testing methodologies suitable for the high-temperature conditions, crucial for NSF processes, have not been adequately addressed. To fill this gap, this study aims to characterize HTC under NSF conditions using a columnar pressing test. The test was conducted at three different temperatures such as 1250, 1300, and 1360 °C and two different pressures, 2 and 8 MPa. During the test, temperature data was collected at the centre of the sample using a k-type thermocouple. Furthermore, the DT of the pressing test was developed and the three-dimensional finite element model of 42CrMo4 steel was constructed using FORGE NxT® 4.0 FEM software. The simulations were performed with varying HTC values to replicate the experimental test data. Inverse modelling techniques were then applied to compare experimental and simulated data, enabling the characterization and optimization of HTC values under NSF testing conditions. The results demonstrated that HTC in the NSF process is primary impacted by the forming pressure, whereas temperature change showed no variation at the studied ranges. The HTC value of 500 W/m2K and 800 W/m2K was identified at 2 MPa and 8 MPa, respectively. The conclusion of this study aims for a better understanding of heat transfer phenomena in NSF processes, enhancing the reliability of DT for industrial applications.

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Sensitivity analysis of near solidus forming (NSF) process with digital twin using Taguchi approach

Sajjad,

Trinidad,

Plata

et al. 2024

Adv. Manuf.

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Forging at near solidus material state takes advantage of the high ductility of the material at the semi solid or soft-solid state while keeping most of the mechanical properties of a forged part. The technology is at maturity level ready for its industrial implementation. However, to implement the process for complex cases the development of an appropriate digital twin (DT) is necessary. While developing a material model, a strong experimental and DT is necessary to be able to evaluate the accuracy of the model. Aimed at having a reliable DT under control, for future material model validations, the main objective of this work is to develop a sensitivity analysis of three NSF industrial cases such as Hook, R spindle and H spindle to develop an adequate DT calibration procedure. Firstly, the benchmark experimentation process parameter noise and experimentation boundary conditions (BCs) parameter uncertainty are identified. Secondly, the three industrial benchmark DTs are constructed, and a Taguchi design of experiments (DoEs) methodology is put in place to develop the sensitivity analysis. Finally, after simulations the results are critically evaluated and the sensitivity of each benchmark to the different inputs (process parameter noise and BC parameter uncertainty) is studied. Lastly, the optimum DT calibration procedure is developed. Overall, the results stated the minimum impact of the material model in terms of dies filling. Nevertheless, even if the material model is the highest impacting factor for the forging forces other inputs, such as heat transfer and friction must be under control first.

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Investigation of influencing factors on friction during ring test in hot forging using FEM simulation

Cited by 5 publications

References 11 publications

Study of the slant fracture in solid and hollow cylinders: Experimental analysis and numerical prediction

Study of the slant fracture in solid and hollow cylinders: Experimental analysis and numerical prediction

Characterization of the heat transfer coefficient at near solidus forming condition using columnar pressing test

Sensitivity analysis of near solidus forming (NSF) process with digital twin using Taguchi approach

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