New schemes of forging plates, shafts, and discs

Abstract

This paper presents the various ways of forging large forged pieces such as shafts, plates, and discs. A finite element method was used to simulate open die forging processes such as forging by flat dies with a slant, forging by staged dies, and upsetting of profiled workpiece. The parameters of the stress strain state of the billet in these processes were determined, along with the rational parameters for forging plates by flat dies with slant such as tool size and mechanical modes. The optimal die step dimension and mechanical regime for forging shafts by staged tools was determined. Also, the rational geometric parameters of the workpiece for forging discs by upsetting were determined. For these forging schemes, a simulation was done of the microstructure evolution in forgings obtained by traditional technology and new proposed technology. The paper shows the advantages of new forging schemes which provide a uniform distribution of grain size in the obtained billets.

Evaluation of metal plasticity and research on the mechanics of pressure treatment processes under complex loading

“…In the experimental tests, a flare at the flange equator arises with a flange diameter of d max =48 mm for a value of r/d 0 =0.25 (r=4.26 mm). The results of the calculations coincide satisfactorily with the results obtained in [1][2][3][4]23].…”

“…Workpieces of the desired accuracy in shape and size can be obtained in one transition or, due to the plasticity resource depletion, in several transitions associated with intermediate annealing to restore the plasticity of the workpiece material. In the second case, non-monotonic processes of plastic shaping can be used with high efficiency, which is also connected with the formulation and solution of new problems in the theory of plasticity [1][2][3][4].…”

Calculation of recovery plasticity in multistage hot forging under isothermal conditions

“…A finite element method (FEM) (Zhbankov and Perig 2013a, b; Zhbankov et al 2014, 2016; Perig et al 2013a, b, 2015) in Deform 3D software was used in the simulation of the upsetting process. The diameter of the billet is 18 mm, the length is 20 mm, and the material is carbon steel with 0.70% C. The initial temperature of the billet is 1100 °C and the initial temperature of the tools is 20 °C.…”

Improving the quality of forgings based on upsetting the workpieces with concave facets

“…Research into the dynamics of forging the axial looseness is reported in paper [16]. Designing the new technological forging processes when making forgings with special purposes requires information on the dynamics of forging the axial defects in an ingot at deformation according to new schemes.…”