Metal flow behavior of P/M connecting rod preform in flashless forging based on isothermal compression and numerical simulation

Li, Fengxian; Chen, Peng; Han, Jin; Long, Deng; Yi, Jianhong; Liu, Yichun; Eckert, J.

doi:10.1016/j.jmrt.2019.11.047

Cited by 13 publications

(12 citation statements)

References 26 publications

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“…This is because of the increased friction created by the contact surfaces. 29 It has been shown by Li et al 19 that the local friction conditions and the geometrical shape of the dies affect the flow of metal during forging.…”

Section: Case Ii: Closed Forging Testmentioning

confidence: 99%

Modelling the Tribological Performance of Palm mid olein in Cold Forging Test using DEFORM-3D

Yahaya

Samion

Abidin

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part J:

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In the past, most metal-forming lubricants used mineral oils or other hazardous compounds as their primary foundation. Due to their non-toxic and biodegradable qualities, vegetable oils have the potential to replace mineral oil as a lubricant. Palm oil's byproduct is presently being researched as a biolubricant in order to expand its market beyond cooking oil. Modeling a finite element approach is one of the excellent predictions in tribological tests, notably in metal forming processes. The purpose of this paper is to serve as a modelling the metal forming process and demonstrate the use of palm mid olein as a biolubricant. The metal forming test is essential to the understanding of materials and engineering research because of the friction, wear behaviour, and deformation it produces. Utilizing aluminum (AA1100) as a specimen, this study compared the results of using palm oil-based metal forming oil to those of using commercial metal forming oil. In order to better understand the forging process, we analyse the material flow patterns of these parts at different die stroke levels. According to the findings, the friction of both tested experiment is slightly different where in ring compression test (RCT) test palm mid olein (PMO) has a higher friction ( m = 0.20 and μ = 0.0937) compare to commercial metal forming oil (CMFO) ( m = 0.15 and μ = 0.075) but in closed forging test, the friction PMO has found to be lower ( m = 0.39/μ = 0.159) compare to the CMFO ( m = 0.42/μ = 0.1675). From the investigated result also, PMO has a potential to be utilized as a metal forming lubricant.

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Section: Case Ii: Closed Forging Testmentioning

confidence: 99%

Modelling the Tribological Performance of Palm mid olein in Cold Forging Test using DEFORM-3D

Yahaya

Samion

Abidin

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part J:

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“…Uniform distribution of deformation is one of the essential requirements for aerospace forgings [5]. While reducing the forming load [6][7][8] and eliminating the forming defects such as underfilling [9][10][11], folds [9,11,12], and cracks [13][14][15], the deformation uniformity should also be guaranteed. The uniformity of deformation inside the forging directly determines the uniformity of forging organization [8,16], and forging internal organization is uniformly distributed by the deformation uniformity decision, and nonuniform organization will lead to reduced fatigue life of forgings or premature failure in the process of use.…”

Section: Introductionmentioning

confidence: 99%

Automatic preform design and optimization for aeroengine disk forgings

Han

Wang

Chen

et al. 2023

Int J Adv Manuf Technol

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To ensure a more uniform microstructure distribution of forging and improve the service performance of aeroengine disk parts, an automated preform design method is proposed for integrated preform shape design and optimization based on the NURBS curve, finite element method (FEM), and genetic algorithm (GA). Firstly, the random preform shape graph is automatically constructed by the NURBS curve design criterion. The volume and shape complexity are used as the constraints of the preform. Then the ratio of the mesh area within the set strain range to the total mesh area is used as the fitness function for the uniformity of deformation, and the genetic algorithm module is used for optimization. Finally, a large disk forging is an example of its optimal design. The results show that the deformation uniformity of the forgings is excellent, its fitness value is as high as 99.59%, and there are no problems such as folding, underfilling, and limited distribution of flash, which verifies the effectiveness of the method. In addition, the method has the advantage of strong universality, which can find the preform shape with good deformation uniformity for any shape forgings.

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“…The best strength-related properties of connecting rods used in the automotive industry are provided by metal forming processes described in the literature [ 4 , 5 , 6 , 7 ]. Die forging described in the specialist literature may serve as a perfect example [ 8 , 9 , 10 , 11 , 12 , 13 ].…”

Section: Introductionmentioning

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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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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Metal flow behavior of P/M connecting rod preform in flashless forging based on isothermal compression and numerical simulation

Cited by 13 publications

References 26 publications

Modelling the Tribological Performance of Palm mid olein in Cold Forging Test using DEFORM-3D

Modelling the Tribological Performance of Palm mid olein in Cold Forging Test using DEFORM-3D

Automatic preform design and optimization for aeroengine disk forgings

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

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