Possibilities of Measuring and Detecting Defects of Forged Parts in Die Hot-Forging Processes

Abstract

This paper presents research results in the field of industrial die forging, mostly related to the use of advanced measuring techniques and tools, numerical simulations, and other IT tools and methods for a geometrical analysis of the forged items as well as detection of forging flaws and their prevention, and optimization of the hot-forging processes. The results of the conducted investigations were divided into three main areas. The first area refers to the application of, e.g., optical scanners and programs related to their operation, data analysis, including the construction of virtual gauges, measurements of selected geometrical features of both the manufactured forgings and their physical and virtual models, as well as an analysis of the durability of the forging tools based on the proprietary reverse scanning method. The second area presents the results of measurements and analyses performed with the use of finite element modeling and by means of some special functions in the calculation packages, such as contact, flow lines, trap, or fold, for the detection of forging defects and an analysis of the force parameters. In turn, the third area presents a combination of different methods of measurement and analysis, both FEM and scanning, as well as other IT methods (physical modeling, image analysis, etc.) for the analysis of the geometry and defects of the forgings. The presented results point to the great potential of these types of tools and techniques in forging industry applications as they significantly shorten the time and increase the accuracy of the measurement, as well as providing a lot of valuable information, physical variables, and technological parameters that are difficult or impossible to determine either analytically or through experimental means. The use and development of these techniques and methods are fully justified, both in the aspect of science and the increased effectiveness and efficiency of production.

Possibilities of Increasing the Durability of Dies Used in the Extrusion Process of Valve Forgings from Chrome-Nickel Steel by Using Alternative Materials from Hot-Work Tool Steels

“…Currently, a number of IT engineering tools and numerical methods based on FEM [19][20][21] are used to analyze and optimize industrial forging processes, often combined with thermal imaging measurements as well as microstructural research or dimensional analysis using laser scanners [22,23]. However, it seems that the most information can be obtained from numerical modeling, because such computational packages allow the determination of many physical quantities and other technological parameters that are difficult or even impossible to determine experimentally [24][25][26], and by introducing new functions verified in industrial conditions, they allow for quick the analysis of the entire industrial process, e.g., determining the distribution of temperatures, stresses, forging forces, flow errors of the deformed material, and even defects in forgings and many other technological aspects [27,28]. Currently, the combination of the above-mentioned research and measurement methods, in particular using increasingly advanced simulation programs based on FEM and FVM, enables comprehensive analysis on the basis of which it is possible to solve many scientific and technological issues [29][30][31].…”

Improvement of the Technology of Precision Forging of Connecting Rod-Type Forgings in a Multiple System, in the Aspect of the Possibilities of Process Robotization by Means of Numerical Modeling

“…More and more often, in FEM [ 40 , 41 ], special functions for flaw detection are applied [ 42 ]. The application of such functions by the user makes it possible to significantly shorten the implementation time of a new project and limit the errors, e.g., during the design of new instrumentation taking into account the gripping by the robots’ grippers [ 43 ]. Although numerical modeling and IT tools [ 44 ] significantly change the role and scope of the experiment to the virtual dimension, the real experiment remains, on the one hand, the best and most necessary verification, and on the other hand, it is the most expensive and time-consuming stage of design [ 45 ].…”

Possibilities of Increasing the Durability of Punches Used in the Forging Process in Closed Dies of Valve Forgings by Using Alternative Materials from Tool Steels and Sintered Carbides

“…Currently, such computational packages (Forge, Simufact, QForm) allow for quick analyses of the entire industrial process, e.g., determining the distribution of temperatures, stresses, forging forces, flow errors of the deformed material, and many other technological aspects [44,45]. Furthermore, by using new, special functions verified in industrial conditions, they even allow for the detection of flaws, like overlapping folds or trapped "pressure pockets", and compare numerical results and z-nominal CAD models [46].…”