Monitoring of process and tool status in forging process by using bolt type piezo-sensor

Kim, Soo‐Young; Ebina, Akifumi; Sano, Asuka; Kubota, Satoshi

doi:10.1016/j.promfg.2018.07.275

“…A sensoric fastener, which could gather the combined force and torque sensor signals in individual spatial directions, was invented to monitor pretensioning forces and operating loads in mechanical connections between components [66]. The method can be suitably applied to the monitoring of process and tool states in forging processes [67]. However, the force measurement is not an effective index for assessing galling because variations in the load are mostly hidden in changes in material properties, formed shapes, lubricating conditions, and other issues.…”

Section: Measurement Methodsmentioning

confidence: 99%

Galling phenomena in metal forming

Dohda

¹

,

Yamamoto

²

,

Hu

³

et al. 2020

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Galling phenomena in metal forming not only affect the quality of the engineered surfaces but also the success or failure of the manufacturing operation itself. This paper reviews the different galling conditions in sheet and bulk metal forming processes along with their evolution and the effects of temperature on galling. A group of anti-galling methods employed to prevent galling defects are also presented in detail. The techniques for quantitatively measuring galling are introduced, and the related prediction models, including friction, wear, and galling growth models, are presented to better understand the underlying phenomena. Galling phenomena in other processes similar to those occurring in metal forming are also examined to suggest different ways of further studying galling in metal forming. Finally, future research directions for the study of galling in metal forming are suggested.

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“…The cold forging process is a method of securing a desired shape by compressing and deforming a material under a high load at room temperature. It is possible to obtain high shape accuracy, but due to the high forming load, seizure often occurs on the surface of the material and die 12 , 13 . This is a direct cause of loss, such as the occurrence of forming defects, increase in manufacturing cost, and decrease in productivity.…”

Section: Introductionmentioning

confidence: 99%

A study on improving the prediction accuracy of cold forging die life based on quantitative evaluation of phosphate film damage

Seo

2023

Sci Rep

1

0

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In designing the multi-stage cold forging process, an important factor along with formability is the die life cycle. As the die life cycle is closely related to the integrity of the phosphate film coating on the surface of the material, this study presents a method for predicting the die life cycle considering damage to the phosphate film coating. First, the correlation between the phosphate treatment conditions (phosphate treatment solution concentration and temperature) and the film layer weight was discussed. Afterwards, the behavior of the friction coefficient according to the damage of the phosphate film was predicted through repeated frictional tests. The behavior of the coefficient of friction was mainly divided into three areas and correlated with the film weight. By applying these results to the automobile engine bolt forging process, a method for performing precise simulation considering the damage to the phosphate film was presented. In addition, a method for predicting the quantitative limit life of the die based on precise simulation results with high accuracy was presented.

show abstract

“…The cold forging process is a method of securing a desired shape by compressing and deforming a material under a high load at room temperature. It is possible to obtain high shape accuracy, but due to the high forming load, seizure often occurs on the surface of the material and die [17][18]. This is a direct cause of loss, such as the occurrence of forming defects, increase in manufacturing cost, and decrease in productivity.…”

Section: Introductionmentioning

confidence: 99%

Life Cycle Evaluation of Cold Forging Die Considering Lubrication Performance of Phosphate Film Coating

Seo

¹

2023

Preprint

0

View full text Add to dashboard Cite

In designing the multi-stage cold forging process, an important factor along with formability is the die life cycle. As the die life cycle is closely related to the integrity of the phosphate film coating on the surface of the material, this study presents a method for predicting the die life cycle considering damage to the phosphate film coating. First, the correlation between the phosphate treatment conditions (phosphate treatment solution concentration and temperature) and the film layer weight was discussed. Afterwards, the behavior of the friction coefficient according to the damage of the phosphate film was predicted through repeated frictional tests. The behavior of the coefficient of friction was mainly divided into three areas and correlated with the film weight. By applying these results to the automobile engine bolt forging process, a method for performing precise simulation considering the damage to the phosphate film was presented. In addition, a method for predicting the quantitative limit life of the die based on precise simulation results with high accuracy was presented.

show abstract

Monitoring of process and tool status in forging process by using bolt type piezo-sensor

Cited by 11 publications

References 1 publication

Galling phenomena in metal forming

Galling phenomena in metal forming

A study on improving the prediction accuracy of cold forging die life based on quantitative evaluation of phosphate film damage

Life Cycle Evaluation of Cold Forging Die Considering Lubrication Performance of Phosphate Film Coating

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