Preform optimization for hot forging processes using an adaptive amount of flash based on the cross section shape complexity

Knust, Johannes; Stonis, Malte; Behrens, Bernd‐Arno

doi:10.1007/s11740-016-0702-7

Cited by 20 publications

(3 citation statements)

References 16 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…However, the stress-strain field during the forging process was superficially discussed. Liu [22][23][24][25] not only reported a numerical simulation optimization analysis of the hot forging of connecting rods on the basis of response surface analysis with experimental verification but also analyzed parameter variables that influence forging loads and mold wearing. The analysis results were only limited to open forging.…”

Section: State Of the Artmentioning

confidence: 99%

High-temperature Rheological Behavior and Numerical Simulation Technology for 6061 Aluminum Alloy Connecting Rods

Zhang¹,

Yu²

2018

JESTR

View full text Add to dashboard Cite

Aluminum alloy connecting rods formed by common hot forging usually exhibit many surface defects, including cracks, folding, and disordered metal streamlines. These defects can considerably influence their performance. A thermosimulation compression experiment on 6061 aluminum alloy was conducted to prevent such defects and disclose the law of precise forging. The true stress-strain curves and stress peak under different deformation temperatures and strain rates were also obtained. The constitutive equation for the high-temperature rheological stress of 6061 aluminum alloy was derived. On the basis of this equation, the multi-field coupling problem of 6061 aluminum alloy connecting rods during closed forging deformation was discussed, and the influences of three forging techniques on forging results were analyzed. Results demonstrate that 6061 aluminum alloy is sensitive to positive strain rates. Steady-state flow stress is inversely proportional to temperature given a fixed strain rate, and flow stress is proportional to strain rate when the deformation temperature is fixed. During the closed forging process of aluminum alloy connecting rods, the upper and bottom punches move first, followed by the lateral punches, thereby resulting in a notable forging effect. Forging quality is inversely proportional to the movement order of lateral punches. In addition, the forging load of aluminum alloy connecting rods first increases and then decreases and finally increases. Forging load is proportional to deformation rate. The proposed method provides an excellent prospect to determine the closed forging technique of aluminum alloy.

show abstract

Section: State Of the Artmentioning

confidence: 99%

High-temperature Rheological Behavior and Numerical Simulation Technology for 6061 Aluminum Alloy Connecting Rods

Zhang¹,

Yu²

2018

JESTR

View full text Add to dashboard Cite

show abstract

“…KNUST ET AL. developed an evolutionary algorithm for a cross wedge rolled preform of a connecting rod [2]. The aim was to avoid a lack of form filling and folds.…”

Section: A Time Savings Within Forging Process Designmentioning

confidence: 99%

Predicting Forming Forces and Lack of Volume with Data Mining Methods for a Flange Forging Process

Rasche¹,

Langner²,

Stonis³

et al. 2017

IJMO

Self Cite

View full text Add to dashboard Cite

In the forging industry, like in many other economic sectors, it is common to simulate forming processes before executing experimental trials. An iterative simulation process is more economic than trials only but still takes a lot of time. A simulation with realistic parameters takes many hours. For an economical production the idea of predicting some main results of the simulation by Data mining was developed. Within this paper, the use of four different Data mining methods for the prediction of certain characteristics of a simulated flange forging process are presented. The methods artificial neural network, support vector machine, linear regression and polynomial regression are used to predict forming forces and the lack of volume. Both are important parameters for a successful simulation of a forging process. Regarding both, forging forming forces and lack of volume after the simulation, it is revealed that an artificial neural network is the most suitable.

show abstract

“…Gao Zhenshan et al proposed an advanced hot forging method for spiral bevel gears which was helpful to improve the defects of insufficient filling of the gear tooth top, large forming load and low service life of die in traditional forging method [8]. Knust J. et al analyzed the impact of the hot-forging preform shape on forging quality, proposed an optimization design method for preform shape and conducted experimental verification [9]. Chen Fuxiao et al used DEFORM-3D software to numerically simulate the forging and forming process of the driven wheel of the spiral bevel gear, and through the analysis of the simulation results, the flow law of the metal material inside the gear was elaborated, and the changes in the parameters and the distribution of the stresses in the forming process were also explained [10].…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Process Parameter Optimization of Warm Forging Near-Net Forming for Spiral Bevel Gear

Wang,

Jiang,

Wei

et al. 2024

Applied Sciences

View full text Add to dashboard Cite

The warm-forging technology of the spiral bevel gear (873 K–1073 K) was studied. Based on the rigid–plastic finite element method, a numerical simulation was carried out by using DEFORM V11.0 software to explore the influence of different process parameters on gear-forming quality and forming force in the process of warm forging. Taking into account the complexity of the geometry of spiral bevel gears and the diversity of the influence factors in the forging process, as determined through nine groups of numerical simulation experiments, this paper systematically analyzed the influence law of different forging speeds, die preheating temperatures, friction factors and workpiece heating temperatures on the effective stress and strain of spiral bevel gears. The best combination of process parameters with minimum forging force was obtained via the orthogonal experiment, which provides a theoretical basis for the optimization design of the precision forging process of spiral bevel gears and also provides a new idea for studying the precision-forging–forming process of other complex parts.

show abstract

Preform optimization for hot forging processes using an adaptive amount of flash based on the cross section shape complexity

Cited by 20 publications

References 16 publications

High-temperature Rheological Behavior and Numerical Simulation Technology for 6061 Aluminum Alloy Connecting Rods

High-temperature Rheological Behavior and Numerical Simulation Technology for 6061 Aluminum Alloy Connecting Rods

Predicting Forming Forces and Lack of Volume with Data Mining Methods for a Flange Forging Process

Numerical Simulation and Process Parameter Optimization of Warm Forging Near-Net Forming for Spiral Bevel Gear

Contact Info

Product

Resources

About