Supplement Metal Forming 2010
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Development of Guidelines for Warm Forging of Steel Parts
Development of Guidelines for Warm Forging of Steel Parts THESIS Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University By Niranjan Rajagopal, B.Tech Graduate Program in Industrial and Systems Engineering The Ohio State University 2014 Master's Examination Committee: Dr.Taylan Altan, Advisor Dr.Jerald Brevick Copyright by Niranjan Rajagopal 2014 ABSTRACT Warm forging of steel is an alternative to the conventional hot forging technology and cold forging technology. It offers several advantages like no flash, reduced decarburization, no scale, better surface finish, tight tolerances and reduced energy when compared to hot forging and better formability, lower forming pressures and higher deformation ratios when compared to cold forging. A system approach to warm forging has been considered. Various aspects of warm forging process such as billet, tooling, billet/die interface, deformation zone/forging mechanics, presses for warm forging, warm forged products, economics of warm forging and environment & ecology have been presented in detail. A case study of forging of a hollow shaft has been discussed. A comparison of forging loads and energy required to forge the hollow shaft using cold, warm and hot forging process has been presented. ii DEDICATION This document is dedicated to my family. iii ACKNOWLEDGEMENTS I am grateful to my advisor, Prof. Taylan Altan for accepting me in his research group, Engineering Research Center for Net Shape Manufacturing (ERC/NSM) and allowing me to do thesis under his supervision. The support of Dr. Jerald Brevick along with other professors at The Ohio State University was also very important in my academic and professional development. -
Chapter 2: Basic Manufacturing Processes
Chapter 2: Basic Manufacturing Processes • Manufacturing processes refer to the processes of producing articles of definite shape, size and properties • In this unit, manufacturing processes involving forging are discussed Mechanical working of metals • Mechanical working of metal refers to plastic deformation of a metal under the action of mechanical pressure to change dimensions, properties and or surface conditions. • Mechanical working processes include a number of processes like Rolling, forging, extrusion, drawing and press working • The stress induced in the part are greater than the yield strength and less than the fracture strength of the material except in sheet metal works like shearing, piercing and blanking Objectives of Mechanical Working of metals 1. To reduce the original block to the finished dimensions. 2. To improve the mechanical properties. 3. Refinement at grain structure. 4. Directional control of "flow lines". 5. Break up and distribution of unavoidable inclusions. Types of Mechanical working 1. Hot working 2. Cold working Hot Working • The working of a metal above their recrystallization temperature at which new grains are formed is called hot working. • The hot working should be carried above the recrystallization temperature but below the melting point. Advantages of hot working • Refinement of grain structure is achieved. • Elimination of porosity and blow holes in steel. • Greater flexibility in chaning shape and size due to reduction in elastic limit. • A uniformity is established due to proper distribution of impurities throughout the mass. • Improved mechanical properties like, ductility, toughness, elongation etc. • The power required to finish the part from ingot is less. • Directional property resulting from a fibre structure is obtained Disadvantages of hot working • Poor surface finish by rapid oxidation or scaling due to high temperature. -
Based on the Robust Design of Gear Die Optimization ∑
International Journal of Research in Engineering and Science (IJRES) ISSN (Online): 2320-9364, ISSN (Print): 2320-9356 www.ijres.org Volume 5 Issue 5 ǁ May. 2017 ǁ PP. 01-04 Based on The Robust Design of Gear Die Optimization Rong Fei1liu Sheng2 1,2(College Of Materials Engineering shanghai University Of Engineering Science，Shanghai 201620,Chian) ABSTRUCT: The article is based on the optimization of bevel gear (the modulus is 5.2 and the max diameter is 157mm) preforming Die, then optimizing the final Die. Due to the finished forging is cold sizing, so the load is higher than preforming, and lead to a higher wear depth. This article will through design the final Die to reduce the wear depth and load. Based on the simulation technology and Taguchi to optimize and analysis the Die scheme. At last, get the best optimization final Die, and instruct the reality production. Keywords: Bevel gear; Die; Taguchi robust design; optimization I.INTRODUCTION The optimization design of the final forging die of the bevel gear of this subject is based on the initial die optimization, and further optimizes the final forging die[1,2]. Since the maximum diameter of the straight bevel gear reaches 157mm, the final forging is cold finishing, so the load required during the forming process is larger, and the die wear is much larger than the pre forged die. So this chapter will be the traditional mold design of bevel gear cold forging and the inspection of the relevant literature based on the design of the two bevel gears finishing die, die die that combined combined bridge with diversion hole and bridge with the boss. -
Extension of the Forming Limits of Extrusion Processes in Sheet-Bulk Metal Forming for Production of Minute Functional Elements
Manufacturing Rev. 7, 9 (2020) © F. Pilz et al., Published by EDP Sciences 2020 https://doi.org/10.1051/mfreview/2020003 Available online at: https://mfr.edp-open.org RESEARCH ARTICLE Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements Florian Pilz, Johannes Henneberg*, and Marion Merklein Institute of Manufacturing Technology, Egerlandstrasse 13, 91058 Erlangen, Germany Received: 28 October 2019 / Accepted: 10 January 2020 Abstract. Increasing demands in modern production pose new challenges to established forming processes. One approach to meet these challenges is the combined use of established process classes such as sheet and bulk forming. This innovative process class, also called sheet-bulk metal forming (SBMF), facilitates the forming of minute functional elements such as lock toothing and gear toothing on sheet-metal bodies. High tool loads and a complex material flow that is hard to control are characteristic of SBMF. Due to these challenging process conditions, the forming of functional elements is often insufficient and necessitates rework. This negatively affects economic efficiency. In order to make use of SBMF in industrial contexts, it is necessary to develop measures for improving the forming of functional elements and thereby push existing forming boundaries. This paper describes the design and numerical replication of both a forward and a lateral extrusion process so as to create involute gearing in combination with carrier teeth. In a combined numerical-experimental approach, measures for extending the die filling in sheet-metal extrusion processes are identified and investigated. Here, the focus is on approaches such as process parameters, component design and locally adjusted tribological conditions; so-called ‘tailored surfaces’. -
Simulation of Forging Processes
Simulation of forging processes Editor’s Foreword Modern technical systems – in the automotive, avi- The description of the use of virtual tools to deve- ation and aerospace sector as well as in mechanical lop intelligent solutions for the implementation of engineering and the field of energy technology – special features, tolerances and component pro- often involve high-performance forged compo- perties should appeal not only to the forging sector nents. Their key role is based on the one hand on and its customers. Likewise, the intention is also to their enormous load-bearing capacity required for win over the younger generation – especially tech- the transmission of high forces and momentums. nically-minded young people who want to actively On the other hand, it can be observed that in times participate in future technologies – for the sector. of increasingly scarce resources there is a growing Furthermore, the description of the entire process demand for efficient industrial production processes chain from product development using modern CA – as is the case for forging. and simulation techniques through the selection of materials to determining the design of procedures Especially in the automotive industry, increasing or combinations of methods can be a valuable aid in demands with respect to lightweight design and apprenticeships and academic studies. power density call for the ever more intensive op- timization of components, which requires the ca- We are pleased to present to all parties interested reful matching of alloy, component geometry and in forging, by means of the EXTRA-Info documen- the many parameters along the entire design and tation as a whole and more specifically with this la- manufacturing process chain. -
Aircraft Metallurgy by 1% Tin
L.N.V.M. Society Group of Institutes, Palam Extn., Part-1, Sec.-7, Dwarka, New Delhi - 45 1 Aircraft Metallurgy (According to the Syllabus Prescribed by Director General of Civil Aviation, Govt. of India) 2 Aircraft Metallurgy L.N.V.M. Society Group of Institutes, Palam Extn., Part-1, Sec.-7, Dwarka, New Delhi - 45 3 FIRST EDITION AIRCRAFT METALLURGY Prepared by L.N.V.M. Society Group o f Institutes * School of Aeronautics ( Approved by Director General of Civil Aviation, Govt. of India) * School of Engineering & Technology ( Approved by Director General of Civil Aviation, Govt. of India) Author Arjun Singh Published By L.N.V.M. Society Group of Institutes H-974, Palam Extn., Part-1, Sec-7, Dwarka, New Delhi-45 4 Aircraft Metallurgy Published By L.N.V.M. Society Group of Institutes, Palam Extn., Part-1, Sec.-7, Dwarka, New Delhi - 45 First Edition 2007 All rights reserved; no part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the publishers. Price : Rs. 250/- Type Setting Anita Gupta Cover Designed by Abdul Aziz Printed at Graphic Syndicate, Naraina, New Delhi L.N.V.M. Society Group of Institutes, Palam Extn., Part-1, Sec.-7, Dwarka, New Delhi - 45 5 Dedicated To Shri. Laxmi Narain Verma [ Who Lived An Honest Life ] 6 Aircraft Metallurgy Preface Material” is the word which is associated with every object existing in the universe. The knowledge of material enhances our understanding of physical world. -
Simulation of Helical Gear Forming of Az31 Magnesium Material
Advances in Science and Technology Research Journal Volume 11, Issue 2, June 2017, pages 187–191 Research Article DOI: 10.12913/22998624/70998 SIMULATION OF HELICAL GEAR FORMING OF AZ31 MAGNESIUM MATERIAL Önder Ayer1 1 Trakya University, Department of Mechanical Engineering, Edirne, Turkey, e-mail: [email protected] Received: 2017.03.15 ABSTRACT Accepted: 2017.05.05 The simulation of helical gear forming is investigated in this study. AZ31 type mag- Published: 2017.06.01 nesium material was selected for workpiece material because of its high specific strength. The finite element method was used to simulate the closed die upsetting method for magnesium material of helical gear upsetting. Three dimensional finite element analyses were carried out to obtain the forming load, effective stress, effective strain and temperature change with DEFORM-3D software. Keywords: AZ31, Gear forming, Helical gears, FEM, DEFORM-3D. INTRODUCTION applicable to internal teeth. The process is rapid and produces a fine surface finish with high di- It is well known that gears were used for ir- mensional accuracy. However, because broaches rigation systems in Mesopotamia. Romans used are expensive and a separate broach is required cast bronze or iron gears for longer service life in for each size of gear, this method is suitable ancient times. Nowadays, gears are used in sever- mainly for high-quantity production. These afore- al areas such as transmissions, complex machines mentioned conventional manufacturing processes and so many different industrial applications. mainly cause the high amount of material loss for Gears are generally manufactured by machining mass production. Conversely, the bulk forming or by a combination of conventional hot forging processes like forging are generally preferred for with machining requiring a lot of manufacturing material savings and much more important than time, which means more expensive manufactur- this; the bulk forming processes improves the me- ing. -
The Optimization of Engine Mounting Parts Using Hot-Cold Forging Technology D
World Academy of Science, Engineering and Technology International Journal of Industrial and Manufacturing Engineering Vol:10, No:4, 2016 The Optimization of Engine Mounting Parts Using Hot-Cold Forging Technology D. H. Park, Y. H. Tak, H. H. Kwon, G. J. Kwon, H. G. Kim resolve these issues. Abstract—The purpose of this study is to develop a forging Forging process is being developed because it can save process of automotive parts that satisfies the deformation materials by reducing chips, which otherwise produced in a characteristics. The analyses of temperature variation and deformation large quantity during conventional cutting process, and to behavior of the material are important to obtain the optimal forging produce net shape parts which are the closest to the products products. The hot compression test was carried out to know formability at high temperature. In order to define the optimum [3]. With hot-cold forging technology, it is possible to prevent forging conditions including material temperature, strain and forging crack at the flange occurred during cold forging and to load, the commercial finite element analysis code was used to simulate supplement weakness due to oxidation and decarbonization the forging procedure of engine mounting parts. Experimental results occurred during hot forging [4]–[9]. were compared with the simulation results by finite element analysis. Existing engine mounting parts are produced by applying a Test results were in good agreement with the simulations. cold forging with a total of nine processes, namely materials cutting and forward extrusion, upsetting, forging, sizing, Keywords—Cold forging, hot forging, engine mounting, annealing in each process, shot blast, and lubrication. -
Download Presenation
Basic Manufacturing Processes Abdul Khader AA Manufacturing Processes • Manufacturing processes refer to the processes of producing articles of definite shape, size and properties • In this unit, manufacturing processes involving forging are discussed Abdul Khader AA Manufacturing Processes Forming Deforming Machining Joining Surface Property Processes processes processes finishing modificati Processes on Casting Forging Turing Welding Metallic Annealing coating Power Extrusion Milling Brazing Normalizing metallurgy Anodizing Rolling Grinding Soldering Tempering Plastic Plastic coating technology Sheet metal Shaping Riveting working Buffing EDM Swaging Lapping Electroplating Thread rolling Abdul Khader AA Mechanical working of metals • Mechanical working of metal refers to plastic deformation of a metal under the action of mechanical pressure to change dimensions, properties and or surface conditions. • Mechanical working processes include a number of processes like Rolling, forging, extrusion, drawing and press working • The stress induced in the part are greater than the yield strength and less than the fracture strength of the material except in sheet metal works like shearing, piercing and blanking Abdul Khader AA Objectives of Mechanical working of metals 1. To reduce the original block to the finished dimensions. 2. To improve the mechanical properties. 3. Refinement at grain structure. 4. Directional control of "flow lines". 5. Break up and distribution of unavoidable inclusions. Abdul Khader AA Classification of Mechanical working 1. Hot working 2. Cold working Abdul Khader AA Hot working • The working of a metal above their recrystallization temperature at which new grains are formed is called hot working. • The hot working should be carried above the recrystallization temperature but below the melting point. Abdul Khader AA Advantages of Hot working • Refinement of grain structure is achieved. -
Basic Principles of Metallurgy and Metalworking
Basic Principles of Metallurgy and Metalworking Course No: T04-009 Credit: 4 PDH Donald Parnell, P.E. Continuing Education and Development, Inc. 22 Stonewall Court Woodcliff Lake, NJ 076 77 P: (877) 322-5800 [email protected] Basic Principles of Metallurgy and Metalworking 1 Basic Principles of Metallurgy and Metalworking Table of Contents Chapter 1: History of Metalwork and Metallurgy Chapter 2: Ore and Metallurgical Processing Chapter 3: Metal Properties and Alloys Chapter 4: Mechanical Properties of Metals Chapter 5: Strength in Metals Chapter 6: Corrosion Resistance Chapter 7: Types of Iron (Ferrous Metals) Chapter 8: Types of Steel (Another Ferrous Metal) Chapter 9: Nonferrous Metals and Alloys Chapter 10: Metalworking Processes Chapter 11: Metal Identification And Testing Methods 2 Basic Principles of Metallurgy and Metalworking Chapter 1: History of Metalwork and Metallurgy 3 Basic Principles of Metallurgy and Metalworking Metals and temperature Throughout history, advances in metalworking correlated with advances in achieving the higher temperatures in our melting of those metals. As we developed the means to achieve higher temperatures in the melting and smelting processes, so too did we advance in our metalworking and alloying technologies. Those ores and metals that could be smelted and melted at lower temperatures were the first to be developed into the weaponry, tools, and jewelry of the day. Metals with lower melting points such as copper, and its alloy bronze, were discovered long before iron and its alloy steel. Also, the pure metals, like copper and iron, were used before their alloys, bronze and steel. 4 Basic Principles of Metallurgy and Metalworking Metals found in ancient history Ancient civilizations knew of seven metals: • Iron • Tin • Lead • Copper • Mercury • Silver • Gold Not all metal required heat in order to be processed. -
Basic Knowledge Forgings – Significance, Design, Production, Application
Introduction Basic Knowledge Forgings – Significance, Design, Production, Application Forgings – Significance, Design, Production, Application 1 Directory Page number Subject 30 Preface 4 - 80 Forging History 9 - 11 Production Statistics 12 - 14 Forging Materials 15 - 16 Grain-Flow 17 Tool Design and Profitability 18 - 19 Accuracy of Forged Pars 20 The most important forging processes 21 - 28 Forging Machinery 29 - 31 Automation 32 - 33 Pre-Forming 34 Ring Rolling 35 - 36 Open-die Forging 37 Special Process Hot Forging 38 Special Process Warm Forging 39 - 47 Cold Forging 48 - 52 Process Stages 53 Process Combinations 54 - 55 Tools 56 - 57 Heat Treatment 58 Surface Treatment 59 - 66 Quality Assurance and Material Testing 67 Machining Process 68 Forged parts in competition 69 - 81 Diversity of Forms 82 - 84 Applications 85 Diversity in Forging Technology 86 Optimization of Components NOTE: 87 - 90 Development Chain Please switch from standard view to 91 - 94 Simulation screen presentation to be able to 95 Sources of Illustrations and Information activate and use the links. 96 Imprint 97 - 101 Bibliography 102 Annex Forgings – Significance, Design, Production, Application 2 Preface Dear Readers, Ladies and Gentlemen, This presentation of the forging industry is designed to offer you an easily comprehensible insight into the highly interesting and, for the economy, tremendously important world of hot and cold forging. Even in the age of the Blackberry, IP-TV, Web 2.0 and all of the other colourful accomplishments that our modern world of the media presents us with every day, machine engineering and plant construction – which is dependent on forged components by massive forming – is and will remain one of the most important pillars of our present-day prosperity. -
INFORMATION to USERS This Manuscript Has
INFORM ATION TO USERS This manuscript has been reproduced fromm the icrofilm master. UMI films the text directly from the original orcopy submitted. Thus, some thesis and dissertation copies are in ^ew riter face, while others may be fromany type of computer printer. The quality of this reproduction is dependent upon the quali^ of the copy submitted. Broken or indistinct print, colored or poor quality illustrations and photographs, print bleedthrough, substandard margins, and in^roper alignment can adversety afreet reproduction. In the unlikely event that the author did not send UMI a complete manuscript and there are missing pages, these will be noted. Also, if unauthorized copyright material had to be removed, a note will indicate the deletion. Oversize materials (e.g., maps, drawings, charts) are reproduced by sectioning the original, beginning at the upper left-hand comer and continuing from left to right in equal sections withsmall overlaps. Each original is also photographed in one exposure and is included in reduced form at the back of the book. Photographs included in the original manuscript have been reproduced xerographically in this copy. Higher quality 6" x 9" black and white photographic prints are available anyfor photographs or illustrations appearing in this copy for an additional charge. Contact UMI directly to order. UMI A Bell & Howell Information Company 300 North Zeeb Road. Ann Arbor. Ml 48106-1346 USA 3l3.'761-4700 80D.'521-0600 An integrated approach to Cost-effective Process Planning and Equipment Selection in cold, warm and hot Forming Dissertation Presented in Partial Fulfillment of the Requirements for the Degree of Doctor of Philosophy in the Graduate School of The Ohio State University By Ravikiran Duggirala, B.E.