Modelling of Induction Heating of Steel Work Piece for Forging of Crankshaft

Janutienė, Rasa Kandrotaitė; Mažeika, Darius

doi:10.5755/j01.ms.24.3.18313

Cited by 3 publications

(1 citation statement)

References 12 publications

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“…В мировой практике имеются ряд исследований по систематизации и уменьшению дефектности поковок коленчатых валов на основе применения простейших инструментов качества [1,2]. Рассматривается применение методов бережливого производства для уменьшения дефектности поковок коленчатых валов [3]. Авторами установлено, что частыми дефектами поковок коленчатых валов после горячей объемной штамповки является не полное заполнение гравюр штампов и деформации.…”

Section: Introductionunclassified

Reduction of Complex Spatial Warping of Crankshaft Forgings to Ensure Guaranteed Allowance for Root and Connecting Rod Necks

Czech¹,

Safarov²

2022

Vestnik IzhGTU imeni M.T. Kalashnikova

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In the article, from the total set of dimensions of the crankshaft forgings, geometric accuracy indicators reflecting their complex spatial warping - the diametrical dimensions of the root and connecting rod necks, angular deviations of the connecting rod necks, the curvature of the third root neck, transverse displacement along the die line - are highlighted. To estimate the value of spatial warping according to the selected accuracy indicators during the period of durability of the engravings of die inserts, a batch of crankshaft forgings was measured, followed by probabilistic and statistical analysis in the form of plotting histograms of distributions, normal distribution curves and Shewhart charts. On the basis of the obtained statistical data of value variability, a combination of their values is considered, leading to scrap of crankshaft forging connecting rod necks in the form of defects caused by forging under-allowance or non-straightness after mechanical processing. Under-allowance for root and connecting rod necks occurs at minimum values of diametrical dimensions and maximum values of angular size deviations, non-straightness along the third root neck and transverse displacement along the die line. It was found that the diametrical dimensions of the root necks range up to 4 mm; for the first, second and the third neck it ranges up to 2 mm, for the second neck - up to 4 mm. To prevent under-allowance, the adjustment is carried out along the upper limit of the tolerance. The range of forging lateral displacements along the die line is up to 0.6 mm, that is close to the upper limit of the tolerance. The curvature of the forging found in different mutually perpendicular directions varies. For the first installation of correction operation is up to 1 mm, for the second installation it is up to 1.5 mm, which requires improvements. The most unstable indicator of the connecting-rod neck relative position is the deviation of their angular position, reaching values up to 2 mm of their positive and negative values. A technical solution for the local modification of the engraving profiles of die inserts for hot forging correction, allowing to improve the calibration scheme of the crankshaft forging and enhance stability of the crankshaft forging manufacture by angular deviations of the connecting rod necks, as well as to reduce bending along the third root neck is considered.

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Section: Introductionunclassified

Reduction of Complex Spatial Warping of Crankshaft Forgings to Ensure Guaranteed Allowance for Root and Connecting Rod Necks

Czech¹,

Safarov²

2022

Vestnik IzhGTU imeni M.T. Kalashnikova

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Induction Heating during Magnetic Pulse Processing of Metals: Perspective Schemes and their Application

Batygin,

Chaplygin,

Shinderuk

et al. 2022

LEPE

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The paper, based on a review of modern literature, highlights the features of the processes of magnetic pulse processing of metals in traditional schemes of technological processes of modern industrial production. New directions of their development are noted, which provide for the transformation of the natural forces of repulsion of the metal of the processed object into the forces of magnetic-pulse attraction while reducing the operating frequencies of the existing fields. The physics of Lenz-Joule heat dissipation is described, the result of which is the induction heating of conductors by Foucault currents in an external electromagnetic field. Examples of the use of induction heating in modern industry are given. Schemes of practical realizationof preinduction heating are offered, which allow to use both autonomous devices for eddy current excitation and stationary connection for the same purpose of additional power source. The possibility of increasing efficiency by increasing the ductility of the metal when heated is noted, as well as its possible limitations associated with increasing the active resistance of metals during the growth of Lenz-Joule heat dissipation. It is offered to use the received results at a choice of design decisions for elements of new schemes of the equipment of magnetic pulse processing of metals.

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Development of Induction Heating System Ensuring Increased Heating Efficiency of the Charge Material in a Forging

Hawryluk

Rychlik²,

Pietrzak

et al. 2022

Materials

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This study performs a complex analysis and review of the currently applied methods of inductively heating the charge material in hot die forging processes, as well as elaborates and verifies a more effective heating method. On this basis, a device for inductive heating using variable frequency inductors was designed and constructed, which made it possible to reduce the scale and decarburization with respect to the heater used so far. In the first place, the temperature distributions in the heater in the function of time were modeled with the use of the CEDRAT FLUX software. The aim of the research was to analyze the temperature gradient and value diversification on the surface and in the material core, as well as to determine the process stability. The following stage was designing and constructing a heater with an automatic system of loading and positioning of the charge on the exit, as well as with a possibility of working in a fully automated system adjusted to the work center. The last stage of investigations was the verification of the elaborated effective heating method on the basis of a short production series and a continuous work for the period of 8 h, both in the quantitative and qualitative aspect (reduced oxidation and decarburization as well as a gradient between the core and the surface). The obtained results confirm the effectiveness of the proposed solution referring to heating the charge material, especially in the aspect of stability and repeatability of the process, as well as a significant reduction in oxidation and decarburization of the material surface.

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Modelling of Induction Heating of Steel Work Piece for Forging of Crankshaft

Cited by 3 publications

References 12 publications

Reduction of Complex Spatial Warping of Crankshaft Forgings to Ensure Guaranteed Allowance for Root and Connecting Rod Necks

Reduction of Complex Spatial Warping of Crankshaft Forgings to Ensure Guaranteed Allowance for Root and Connecting Rod Necks

Induction Heating during Magnetic Pulse Processing of Metals: Perspective Schemes and their Application

Development of Induction Heating System Ensuring Increased Heating Efficiency of the Charge Material in a Forging

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