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Development of Guidelines for Warm Forging of Steel Parts

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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. I would also like to thank the Forging Industry Association (FIA) and the Forging Industry Educational and Research Foundation (FIERF) for funding this research. Sincere thanks are extended to all the students and visiting scholars of ERC for their help and suggestions in different parts of this research work. Special thanks go to Siddharth Kishore, Adam Groseclose, Xi Yang, Ganapathy Srinivasan, Tingting Mao, Soumya Subramonian, Eren Billur, Varun Nandakumar, Akshay Jain, Neeraj Joshi and Linda Anastasi as well as many others for their help and encouragement. Lastly, I would like to thank my family for their support and encouragement during my graduate studies. iv VITA March 28 th 1989 ...................................... Born, Coimbatore, India 2010 ....................................................... B.Tech. Mechanical, Amrita University Coimbatore, India 2010-2011 .............................................. Programmer Analyst Trainee, Cognizant Technology Solutions, India. 2012-2013 ............................................. Graduate Research Associate, Engineering Research Center for Net Shape Manufacturing, The Ohio State University FIELD OF STUDY Major Field: Industrial and Systems Engineering v TABLE OF CONTENTS ABSTRACT ...........................................................................................................ii DEDICATION ....................................................................................................... iii ACKNOWLEDGEMENTS .....................................................................................iv VITA ..................................................................................................................... v LIST OF TABLES .................................................................................................ix LIST OF FIGURES ...............................................................................................xi CHAPTER 1 INTRODUCTION ......................................................................... 1 1.1 Forging ................................................................................................... 2 1.2 Warm forging Operation as a System .................................................... 9 CHAPTER 2 BILLET ...................................................................................... 11 2.1 Materials ............................................................................................... 11 2.2 Forging Temperature Range ................................................................ 13 2.3 Determination of Material Properties (Flow stress) .............................. 15 2.3.1 Plain Carbon Steel, 0.15% carbon .................................................... 19 2.3.2 16MnCr5(SAE5115) ......................................................................... 20 2.3.3 AISI ( E52100,4140,1053,5117) ....................................................... 21 vi 2.3.4 42CrMo4 (AISI 4140), 100Cr6 (AISI 52100), 15CrNi6 (AISI 3115), 20MnCr5 (SAE 5120) and Ck15 (AISI 1015) ............................................... 23 2.4 Billet preparation .................................................................................. 23 2.4.1 Physical Aspects............................................................................... 25 2.4.2 Heating ............................................................................................. 25 2.4.3 Pre-coating ....................................................................................... 26 CHAPTER 3 TOOLING .................................................................................. 27 3.1 Tool Design .......................................................................................... 27 3.2 Tool Materials ....................................................................................... 29 3.3 Tool Wear ............................................................................................. 40 3.4 Tool Coatings and Surface Treatments ................................................ 41 CHAPTER 4 BILLET-DIE INTERFACE .......................................................... 43 4.1 Lubrication system ............................................................................... 43 4.2 Types of lubricants ............................................................................... 44 4.3 Application ............................................................................................ 47 4.3.1 Lubricant volume and die temperature ............................................. 49 4.3.2 Lubrication film thickness and die life ............................................... 51 CHAPTER 5 DEFORMATION ZONE/ FORGING MECHANICS .................... 53 5.1 Case study - Hollow Shaft Forging ....................................................... 53 vii CHAPTER 6 PRESSES FOR WARM FORGING ........................................... 62 CHAPTER 7 WARM FORGED PRODUCTS .................................................. 65 7.1 Physical Properties............................................................................... 65 7.2 Mechanical Properties .......................................................................... 67 CHAPTER 8 ECONOMICS OF WARM FORGING ........................................ 68 CHAPTER 9 ENVIRONMENT AND ECOLOGY ............................................. 69 REFERENCES ................................................................................................... 72 APPENDIX A: FLOW STRESS OF STEELS ...................................................... 77 APPENDIX B: TOOL STEELS........................................................................... 85 APPENDIX C: SUPPLIERS ................................................................................ 92 viii LIST OF TABLES Table 1-1: A Comparison of Typical Forging Process Characteristics [ICFG 2001] ............................................................................................................................................. 4 Table 1-2: Advantages and Disadvantages of cold, warm and hot forging processes .......................................................................................................................... 7 Table 2-1: Examples of Warm Forgeable Steels. [Shichun, 1982], [Sheljaskov, 1994] ................................................................................................................................. 12 Table 2-2: Chemical composition of different steels [Neugebauer, 2003] ............ 12 Table 2-3 : Chemical composition of stainless steels [Shichun, 1982] .................. 13 Table 2-4: Warm Forging temperature ranges of stainless steels. [Shichun, 1982] ........................................................................................................................................... 14 Table 2-5: Deforming force in warm upsetting Cr12Mn5Ni4Mo3Al. [Shichun, 1982] ................................................................................................................................. 14 Table 2-6: Rapid oxidation temperatures of stainless steels [Shichun, 1982] ...... 15 Table 2-7: Symbols of flow stress, strain, strain rate and ductility. ........................ 17 Table 3-1: Composition of materials considered suitable for extrusion tooling [Altan, 2011] .................................................................................................................... 31 Table 3-2: Tool Steels used in Warm Forging. [Sheljaskov, 1994] ........................ 35 Table 4-1: Mean tool service life. [Sheljaskov, 2001] ............................................... 45 ix Table 4-2: Die lubricants & billet coatings developed for warm forging. Deltaforge – Henkel, LUBRODAL - Fuchs [www.henkelna.com/metals] [www.fuchs-
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