Abstract
Abstract The aim of this work is to develop a numerical subroutine for the commercial finite element method software QFORM VX 8.1.4 capable of predicting, simultaneously, regions of closed dies which are prone to thermal fatigue as well as the number of cycles required for thermal fatigue cracking. The numerical subroutine was based on Manson (thermal fatigue) and Coffin-Manson (number of cycles) equations. Hot forging of AISI 1045 grinding balls using AISI H13 closed dies was performed and the numerical and experimental results were compared. The findings indicated that after forging 66 grinding balls, the numerical model achieved steady state for the temperature inside the die. After forging 600 grinding balls, both the experimental and numerical results showed that the regions of the dies subjected to the highest thermal gradient were prone to thermal fatigue. In addition to that, the numerically predicted values for the onset of thermal cracking were consistent with the experimental results: 517 and 600 cycles, respectively.
Highlights
The metallurgical sector has a significant importance to the global economy, with vast segments of the productive chain connected to metallurgy, machining and manufacturing
This paper aims to complement the studies by Magalhães et al.[9] in which a numerical subroutine was developed to determine the number of cycles required to initiate thermal cracks in regions prone to low-cycle thermal fatigue
The proposed subroutine was able to predict the regions of the lower die where thermal fatigue occurred during the experimental work
Summary
The metallurgical sector has a significant importance to the global economy, with vast segments of the productive chain connected to metallurgy, machining and manufacturing. The global metal forging market was estimated in USD 78.60 billion in 2018 and a growth of 7.6% is expected between 2019 to 20252. The production of forged component with high surface and dimensional quality at low cost requires that all steps involved (cutting, heating, forging, trimming, etc.) be constantly monitored. Among these production steps, forging itself is the most costly, since dies can represent 10 to 30% of the total cost of a forged part or mechanical component[3]
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