Simulation of 1.2765 DIN steel billet and crack analysis during the forging process using DEFORM 3D software

Kumar, Abhishek; Parameshwaran, R.; Rathanasamy, Rajasekar

doi:10.1002/mawe.202000191

Cited by 4 publications

(5 citation statements)

References 21 publications

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“…It requires three steps: pre-cleaning using the penetrant for 5 min, followed spraying a developer to remove the penetrant on the surface, and visual crack inspection. Penetrant testing was used by Huang et al to locate internal cracks in an original process and to verify that there were no cracks resulting from a new process [9].…”

Section: Internal and External Defect Inspectionmentioning

confidence: 99%

“…Poor design can lead to external and/or internal defects in the workpiece [1][2][3]8]. For example, internal or external cracks were found in gas fitting parts that were caused by residual stress resulting from an unsuitable design of a multi-stage upset forging process [9]. Furthermore, the angle and radius of the die is also important.…”

Section: Introductionmentioning

confidence: 99%

“…Recently, there have been some improvements to the multi-stage upset forging processes to address the workpiece cracking issue using a finger tool to flip the billet upside down. This method diminished cracks on a gas filling part produced by a five-step upset forging process [9]. Once a pressing force is applied, the distribution and direction of metal flow must be investigated since mechanical properties, such as tensile and impact strength, are significantly affected by metal flow lines [17].…”

Section: Introductionmentioning

confidence: 99%

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Design of the semi-closed die for shaping the thick coin-like carbon steel parts in a single operation

Jhonthong,

Talangkun

2023

SN Appl. Sci.

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The current study strives to improve the precision and accuracy of a die and reduce unnecessary production steps. Upset cold forging for thick coin-like carbon steel parts were studied and redesigned for a single operation. The slug used in this experiment was an annealed AISI 1020 carbon steel bar sheared into cylinders having a height to diameter ratio (h0/d0) of 2.07. The design problem is to prevent an inclined slug surface due to surface roughness when it is loaded in the die cavity. The redesigned die is semi-closed with a fixed support at a position 0.25 of the initial height of the slug. Six springs were employed to set the start-to-finish position during forging. The results showed that slugs with rough and uneven surfaces, with an h0/d0 ratio of 2.07, could successfully undergo a single forging. Furthermore, the upset forged coin was designed to have a straight 2.4 mm outer edge, providing area for a set of mechanical fingers to grasp the workpiece during transfer to subsequent steps in the work process of a vertical and/or horizontal forging die set.

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Section: Internal and External Defect Inspectionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Design of the semi-closed die for shaping the thick coin-like carbon steel parts in a single operation

Jhonthong,

Talangkun

2023

SN Appl. Sci.

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“…A three-dimensional forging process was numerically computed in a physio-thermal environment. All physio-thermal properties have been computed using the software at each element and time step [24][25][26][27][28][29]. The final component was only the forging component that matched the finished part shown in Figure 1a; the remaining materials needed to be removed after the forging process as scrap.…”

Section: Properties Analysis Of Finished Part At Different Pointsmentioning

confidence: 99%

Effect of Titanium Based Alloys on Thermo-Mechanical Behavior in 3D Forging Simulation

Raj¹,

Madheswaran²,

Alrubaie³

et al. 2022

Metals

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Titanium has been one of the traditional metals used in the medical industry since 1940. This work modeled and simulated a hip-joint replacement implant using Creo 5.0 and DEFORM 3D (v11.0), respectively. Four titanium-based billets were modeled; out of four billets, three billets were coated with a specified thickness, and one was uncoated. Among the three coated billets, one billet was coated with a 500-micron and two billets coated with a 1000-micron thickness. At the end of the simulation, the coating materials formed patches on the surface of the forged parts. The coating material Ti-6Al-4V (high O2) produced excellent mechanical properties in contrast to the CP-Ti material, which displayed low mechanical properties and did not match the core property. Hence, it was suggested to provide a bulk coating of Ti-6Al-4V (high O2) on the billet to improve the physio-mechanical properties and biocompatibility. Four points were selected on the surface of the forged parts at different locations for identifying the property variations concerning forging time. Results found that coating thickness required more on the side surface of the billet material than on the upper and lower surfaces to enhance its properties.

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“…The simulation of cutting process is an emerging technique, which reduces production cost and time. Deformation of the workpiece have been produced during machining process because of plastic deformation and friction between workpiece and tool [1, 2]. The major advantage of simulation process is the ability to predict mechanical and thermal characteristics of both tool and workpiece.…”

Section: Introductionmentioning

confidence: 99%

2D FEM simulation and experimental verification of Al 7075‐T6 during turning process

Kumar¹,

Rathanasamy²,

Parameshwaran³

2022

Materialwissenschaft Werkst

Self Cite

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In this work, temperature distribution, effective stress and strain distribution in Al 7075‐T6 material and plastic flow of materials during turning process have been studied using Deform 3D v11.0 software. The four different points (P1, P2, P3, and P4) were chosen at the different locations in the cylindrical workpiece and the graph has been plotted with different parameters namely, temperature distribution, effective stress and strain. For temperature distribution, a good agreement has been found between simulation and experimental results at P4. The following results obtained from the simulation: In tertiary zone, the maximum temperature of specimen reaches upto 142 °C at points P1 due to friction between the tool rack face and the lower surface of chip. Maximum effective stress value reaches upto 650 MPa and 704 MPa at P1 and P4 respectively in the first sticking zone due to the combined effect of high normal force by tool edge and ploughing force. The effective strain value at P1 and P4 obtained, strain at P4 reaches maximum compare to P1 due to friction and unven temperature distribution. Additionally, chip analysis has been performed with microscopic image.

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Simulation of 1.2765 DIN steel billet and crack analysis during the forging process using DEFORM 3D software

Cited by 4 publications

References 21 publications

Design of the semi-closed die for shaping the thick coin-like carbon steel parts in a single operation

Design of the semi-closed die for shaping the thick coin-like carbon steel parts in a single operation

Effect of Titanium Based Alloys on Thermo-Mechanical Behavior in 3D Forging Simulation

2D FEM simulation and experimental verification of Al 7075‐T6 during turning process

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