Abstract
Rebielskij-type design of a rolled con rod preform and appropriate upper and lower dies are presented. The proposed process was tested by Simufact Forming program and modifications made to satisfy the criteria of shape, stress and strain state and temperature distribution during processing. Based on the CAD documentation, a STL file was prepared for 3D polymer printing the die, the con rod preform and the forging. The results will enable 3D printing of prototypes in the appropriate metallic materials, leading to tool manufacture and processing in industrial conditions.
Highlights
Manufacturing complex geometries which are impossible to obtain by machining is attained by additive manufacturing
Quality of filling the die shape needed a correction of the diameter of the preform (Step 6)
More homogenous distribution of equivalent strain, stress and temperature appear in the forging after Rebielskji type – preform correction
Summary
Manufacturing from appropriate metallic material takes place after verification of polymer printed models. In this paper the sequence of stages of forging of an aluminium alloy conrod, up to 3D polymer printing of the required shape and size, is presented. Drawing the shape of the forging and preform, by the method of Rebielskij [5], and of the die set [2, 5].
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