Process analysis of multistage forging by using finite element method

Park, K.S.; Tyne, C. J. Van; Moon, Young Hoon

doi:10.1016/j.jmatprotec.2006.11.036

Cited by 53 publications

(27 citation statements)

References 6 publications

(5 reference statements)

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“…The general output from this research was twofold. Simulations of manufacturing chains are common [1][2][3][4][5][6][7][8][9][10] and optimization task for the whole chain based on metal forming can be formulated. On the other hand, connection of the optimization methods with simulation of manufacturing chain requires unacceptably long computing times.…”

Section: Manufacturing Chain For Fasteners and Applied Modelsmentioning

confidence: 99%

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Application of Numerical and Physical Simulation to Design of the Best Manufacturing Technology for Fasteners

Kusiak¹,

Skóra²,

Rauch³

et al. 2015

Archives of Metallurgy and Materials

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The development of the best manufacturing technology for fasteners was the subject of this work. Physical and numerical simulations were used to evaluate various technological variants. Possibility of application of new generation bainitic steels was considered, as well. Improvement of exploitation properties was the objective of the optimization having in mind tool wear and manufacturing costs as constraints. Several fasteners were investigated but results for three parts, including Allen screw, screw anchors used to carry concrete plates are presented as a case study. Industrial trials were performed and confirmed correctness of the designed manufacturing technology.Keywords: forging, fasteners, optimization Przedmiotem pracy była metodyka projektowania najlepszej technologii wytwarzania elementów złącznych. Różne warianty technologiczne były przedmiotem symulacji fizycznych i numerycznych. Rozważono również możliwość zastosowania nowych materiałów w postaci stali bainitycznych. Celem optymalizacji była poprawa własności eksploatacyjnych wyrobów natomiast zużycie narzędzi i koszty wytwarzania wprowadzono jako ograniczenia. Rozważono cały szereg elementów złącznych ale w pracy zamieszczono wyniki dla trzech wyrobów, a mianowicie śruby imbusowej, kotwy do betonu oraz niestandardowej śruby z kwadratową główką. Wykonane próby przemysłowe potwierdziły prawidłowość zaproponowanych technologii wytwarzania tych elementów.

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Section: Manufacturing Chain For Fasteners and Applied Modelsmentioning

confidence: 99%

“…Papers dealing with modelling of the multi-stage forging have been published during the last fifteen years [1,2,3]. In some works a particular focus was on the analysis of workability during this process.…”

Section: Introductionmentioning

confidence: 99%

Application of Numerical and Physical Simulation to Design of the Best Manufacturing Technology for Fasteners

Kusiak¹,

Skóra²,

Rauch³

et al. 2015

Archives of Metallurgy and Materials

View full text Add to dashboard Cite

show abstract

“…transmission and a driven wheel, and has mainly been manufactured adopting the multi-stage warm forging process [9]. For the conventional multi-stage warm forging process in Fig.…”

Section: Conventional Forging Sequence For the Outer Racementioning

confidence: 99%

“…Warm and hot forging processes have several advantages in manufacturing in that the required forging load, and the processing duration for each operation can be reduced [7][8][9]. Recently, demand for various forged components with complex shape has steadily increased, but conventional forging schemes have limitations in meeting requirements such as fast lead-time, low-cost production, and complexity of desired shapes [10][11][12].…”

Section: Introductionmentioning

confidence: 99%

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Process Simplification of Multi-Stage Forging for the Outer Race of a CV Joint

Kim²,

Kang

2014

Materials and Manufacturing Processes

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Constant velocity (CV) joint with six inner ball grooves has been conventionally produced by a multi-stage warm forging process that includes forward extrusion, upsetting, backward extrusions, necking, ironing, and sizing. In this study, multi-stage cold forging is presented with four simplified stages of forward extrusion, modified upsetting, backward extrusion, and combined necking-ironing-sizing. A three-dimensional numerical simulation is performed to ensure the appropriateness of the proposed process, and experimental investigations are carried out using spheroidized and phosphophyllite-coated SCr420H billet material. It is shown that the proposed multi-stage cold forging process could be successfully applied to the production of the outer race.

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Feasibility of using Continuously Cast Round Bloom as a Substitute to Cast Ingot in the Manufacture of Heavy Forgings

Kim

Kang

et al. 2020

steel research int.

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Continuously cast large round blooms have gained widespread attention due to the improved quality, enhanced economy, higher yields, and lower operating costs obtained through continuous operation. Because the continuous casting (CC) process combines the cleanliness and radial solidification symmetry of the ingot casting process with the higher axial symmetry obtainable through bloom casting, it can deliver a more homogeneous product than conventional ingot casting. Herein, the shop floor manufacturing of a main shaft is discussed to confirm the feasibility of using continuously cast round bloom in the manufacture of heavy forgings. For comparison, the characteristics of a 1000 mm‐diameter continuously cast round bloom are assessed against those of a conventionally cast 20.6 ton ingot. To eliminate cavities at the centerline of the cylindrical bloom, additional studies on void closure efficiency at the center of the billet under various forging die geometries (e.g., flat, V, and round dies) are conducted, and the results reveal that the V‐die geometry is most effective in consolidating centerline voids. A comparison of the respective operational characteristics reveals that the round bloom CC method could be feasibly applied in the manufacture of main shafts.

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Process analysis of multistage forging by using finite element method

Cited by 53 publications

References 6 publications

Application of Numerical and Physical Simulation to Design of the Best Manufacturing Technology for Fasteners

Application of Numerical and Physical Simulation to Design of the Best Manufacturing Technology for Fasteners

Process Simplification of Multi-Stage Forging for the Outer Race of a CV Joint

Feasibility of using Continuously Cast Round Bloom as a Substitute to Cast Ingot in the Manufacture of Heavy Forgings

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