Drop Forging Research Articles

Modernizacja procesu kucia matrycowego na przykładzie kształtowania odkuwki wspornika

Modernizacja procesu kucia matrycowego na przykładzie kształtowania odkuwki wspornika

Analysis of the Impact of the Machine on the Forging Process of a Connecting Rod using Numerical Simulation

The application of numerical simulations of production technologies, using the finite element method or the finite volume method, is a widely used approach in advanced engineering design and research. Unlike industrial experiments, this approach allows the analysis of the influence of different process parameters on the output performance of a workpiece. The paper analyzes the influence of the choice of the machine on the forging process of the connecting rod, which is made, among other things, for the needs of the auto industry. For this purpose, numerical experiments were carried out, using the finite volume method and the Simufact.forming software package, with variations of three types of forging machines: drop forging hammer, crank press and screw press. Finally, the results of the numerical experiments and conducted analyses are presented, with concluding considerations and recommendations.

The effect of Anal Sevana (exposure to heat) on Raktavaha srotas: A Case Control Study

Background: Occupational hazard is any workplace condition that causes a risk to employee health. In recent era, a lot of research work is being done on occupational hazards of which continuous exposure to heat is one of the major factors affecting occupational health. A human being has been exposed to heat through various sources like chemicals, forging works etc. Industrial heat when combined with manual work may often make adverse effects on health of the workers and mostly it affects the Raktvaha Srotas according to Ayurved. In this study, attempt had been made to find out what is the percentage of predominance of symptoms of Raktavaha Srotodushti in individuals having continuous exposure to heat. Method: A case control study was carried out in 150 workers from leading manufacturer of Upset forgings and Drop forgings in Pune industrial zone to find out association between exposure to heat and Raktavaha srotodushti symptoms, study group 100 workers (direct exposure to heat), control group 50 workers and filled a questionnaire consisting of symptoms related to raktavaha srotas vititation due to heat exposure. Result: Number of symptoms present in the study group were more than that present in control group. Redness of eyes (100%), thirst (100%), sweating (100%), mental irritation (69%) etc. other Raktavaha srotodushti lakshanas were also observed. Conclusion: Exposure to heat is one of the major causative factors of vitiation of Raktavaha Srotas. Raktavaha srotodushti lakshanas like mukhpaka, shirarshul, santapa, raktapitta observed moderately and vidradhi, pidaka were observed very rarely. To prevent the effects of continuous exposure to heat, the individuals should take preventive majors as prescribed in Ayurveda.

Discrimination of Surface Topographies Created by Two-Stage Process by Means of Multiscale Analysis.

The fundamental issue in surface metrology is to provide methods that can allow the establishment of correlations between measured topographies and performance or processes, or that can discriminate confidently topographies that are processed or performed differently. This article presents a set of topographies from two-staged processed steel rings, measured with a 3D contact profilometer. Data were captured individually from four different regions, namely the top, bottom, inner, and outer surfaces. The rings were manufactured by drop forging and hot rolling. Final surface texture was achieved by mass finishing with spherical ceramic media or cut wire. In this study, we compared four different multiscale methods: sliding bandpass filtering, three geometric length- and area-scale analyses, and the multiscale curvature tensor approach. In the first method, ISO standard parameters were evaluated as a function of the central wavelength and bandwidth for measured textures. In the second and third method, complexity and relative length and area were utilized. In the last, multiscale curvature tensor statistics were calculated for a range of scales from the original sampling interval to its forty-five times multiplication. These characterization parameters were then utilized to determine how confident we can discriminate (through F-test) topographies between regions of the same specimen and between topographies resulting from processing with various technological parameters. Characterization methods that focus on the geometrical properties of topographic features allowed for discrimination at the finest scales only. Bandpass filtration and basic height parameters Sa and Sq proved to confidently discriminate against all factors at all three considered bandwidths.

Numerical Simulation of the Phase Transformations in Steels: A Case Study on Newly-Developed Multi-Phase Steels for Drop Forgings

Numerical Simulation of the Phase Transformations in Steels: A Case Study on Newly-Developed Multi-Phase Steels for Drop Forgings

Calculations of efficiency in implementing progressive mold forming methods

The article provides a classical prime cost accounting, outlining steps for calculating the cost at production site. The calculations compare two methods of manufacturing titanium parts for the aviation industry. The first method uses the mold forming by drop forging and the second one uses a modern superplastic manufacturing technology. This comparative calculation will determine the price of production of one set of parts for the SU-30. The considered methods of manufacturing parts will show the prime cost of production and will draw conclusions on further cooperation between Irkutsk Aviation Plant and Irkutsk State Technical University in the field of titanium products mold forming for modern aircraft.

Ni nanocluster composites for enhanced impact resistance of multilayered arc-PVD ceramic coatings

Optimally, hard protective coatings should effectively absorb impact energy to reduce the likelihood of failure events. In this work, an arc-PVD approach was utilised for the deposition of thick ceramic multilayer AlCrTiN/CrN-based coatings containing a distribution of metallic nickel inclusions throughout sequential CrN-based interlayers. The aim of such coatings is to provide resistance to impact loading in intensive application environments, such as drop forging of steel and turbine blades exposed to abrasive particles. The structure and micro-structural development of the ceramic was first investigated using transmission electron microscopy, where discrete Ni inclusions were observed as both larger discs (d ~ 600–800nm, h ~ 200nm) and smaller (d ~ 50nm) nanoclusters. Confirmation of the distribution and nanocluster chemistry was achieved using atom probe tomography. For mono-block coatings, XRD data showed drastically reduced internal stresses as a result of the Ni inclusions, enabling the creation of thicker protective coatings which minimise substrate stress concentration upon loading. Nickel inclusion additionally provides a softening of the containing hard ceramic layer, allowing for tuning of mechanical properties. Supporting this idea, in situ micropillar compression measurements of the multi-layered coating systems showed that Ni clusters hindered crack propagation through the coating during failure, while the fracture strength could be increased by incorporating both Ti and Ni in the softer CrN-based layer. High-load impact testing highlighted the influence of Ni ‘shock absorbers’ in reducing circumferential cracking, which was further confirmed by an industrial die forging test that demonstrated a 15–22% life-time increase compared to a much thicker hard-chrome plated reference. The results of this study demonstrate an exciting way to produce Ni nanocluster integrated hard ceramic multi-layers using arc-PVD in a single processing step. Such tuneable thin-film composite systems show great promise in minimising damage from impact loading, even under severe working conditions such as in hot forging.

A study of a new screw press forging process for producing aircraft drop forgings made of magnesium alloy AZ61A

PurposeThe aim of this study is to develop a die forging process for producing aircraft components made of magnesium alloy AZ61A using a screw press.Design/methodology/approachThe proposed forging technique has been developed based on the results of a numerical and experimental research. The required forging temperature has been determined by upsetting cylindrical specimens on a screw press to examine both plasticity of the alloy and the quality of its microstructure. The next stage involved performing numerical simulations of the designed forging processes for producing forgings of a door handle and a bracket, both made of magnesium alloy AZ61A. The finite element method based on simulation programme, Deform 3D has been used for numerical modelling. The numerical results revealed that the forgings are free from material overheating and shape defects. In addition to this, the results have also helped determine the regions that are the most prone to cracking. The final stage of the research involved performing forging tests on a screw press under industrial conditions. The forgings of door handles and brackets were made, and then these were tested for their mechanical and structural properties. The results served as a basis for assessing both the viability of the designed technique and the quality of the produced parts.FindingsThe experimental results demonstrate that aircraft components made of magnesium alloy AZ61A can be produced by die forging on screw presses. The results have been used to determine the fundamental parameters of the process such as the optimum forging temperature, the method of tool heating, the way of cooling parts after the forging process, and the method of thermal treatment. The results of the mechanical and structural tests confirm that the products meet the required quality standards.Practical implicationsThe developed forging technique for alloy AZ61A has been implemented by the forging plant ZOP Co. Ltd in Swidnik (Poland), which specializes in the manufacturing of aircraft components made of non-ferrous metal alloys.Originality/valueCurrently, the global tendency is to forge magnesium alloys (including alloy AZ61A) on free hydraulic presses using expensive die-heating systems. For this reason, the production efficiency of such forging processes is low, while the manufacturing costs are high. The proposed forging technique for alloy AZ61A is an innovative method for producing forgings using relatively fast and efficient machines (screw presses). The proposed forging method can be implemented by forging plants equipped with standard stocks of tools, which increases the range of potential manufacturers of magnesium alloy products. In addition, this technology is highly efficient and ensures reduced manufacturing costs.

Identification of the Cause of the Stem Neck Fracture in the Hip Joint Endoprosthesis

Endoprosthesis stem fractures are among the rarest complications that occur after hip joint arthroplasty. The aim of this paper is to evaluate the causes of the fractures of the Aura II stem neck, which is an element of an endoprosthesis implanted in a patient. In order to achieve it, a radiogram was evaluated, the FEM analysis was carried out for the hip joint replaced using the Aura II prosthesis and scanning tests as well as a chemical analysis were performed for the focus of fatigue. The tests performed indicate that the most probable causes leading to the fatigue fracture of the Aura II stem under examination were material defects in the process of casting and forging (forging the material with delamination and the presence of brittle oxides and carbides) that resulted in a significant reduction of strength and resistance to corrosion. In the light of an unprecedented stem neck fracture, this information should be an indication for non-destructive tests of ready-made stems aiming to discover the material and technological defects that may arise in the process of casting and drop forging.

The rationalization of production of magnesium alloy drop forgings using FEM simulation regarding forging process

The rationalization of production of magnesium alloy drop forgings using FEM simulation regarding forging process

Experimental Research Regarding the Plastic Flow of Aluminium Alloy EN AW-7075 in Closed-die Forging Without Flash

The paper describes an innovative method of production of non-ferrous drop forgings, a manufacturing method based on closed die forging without flash. From economic point of view, this method is very interesting for production, due to small quantity of lost material. The research was verified using DEFORM 3D software. In this way can be better understood the principles of forging process and can be analyzed the plastic flow of the material into the die cavity. This experiment was successfully performed at laboratory conditions and the results will be applied in practice.

Evaluation of high-level noise exposures for non-military personnel

Noise-induced hearing loss is often attributed to exposure to high-level impulsive noise exposures from weapons. However, many workers in industries such as mining, construction, manufacturing, and services are exposed to high-level impulsive noise. For instance, construction workers use pneumatic tools such as framing nailers that can produce impulses at levels of 130 dB peak sound pressure level or greater. Miners have exposures to roof bolters and jack-leg drills that produce more of a continuous, but highly impulsive noise. In some areas of manufacturing the exposures include drop forge processes which can create impacts of more than 140 dB. Finally, in the services sector, law enforcement personnel who maintain proficiency with firearms experience the full gamut of small-caliber firearms during training. This paper will examine the noise exposures from recordings that the NIOSH Hearing Loss Prevention Team have collected. The noises will be evaluated with different damage risk criteria for continuous and impulse noise where appropriate.

The Rationalization of Production of Ring-Shaped Drop Forgings Using Computer Simulation of Closed-Die Forging Process

The rationalization of ring-shaped drop forgings production may be considered from different points of view. Important aspects of evaluation and selection of optimal production alternative are material and energy savings and issue of forging tool life. This contribution describes advanced technology of closed die forging without flash, which represents an effective method of manufacture of ring-shaped drop forging from steel alloy type 16MnCr5. This proposed method offers a cheaper possibility of production of mentioned forging piece resulting from saving of batch material. At present drop forgings with this shape are produced by an uneffective method, i.e. die forging with flash, which brings a considerable material loss. Simulation software determined for simulation of bulk forming processes have an important position at development of new advanced technologies of drop forgings production. A simulation program MSC.SuperForge described in this contribution was used in order to verify correct plastic flow of material in closed die cavity.

Design of Controlled Processing Conditions for Drop Forgings Made of Microalloy Steel Grades for Mining Industry

Abstract Effect of plastic processing and controlled cooling on microstructure and mechanical properties of experimental steel grades with microalloyed with Ti, V and/or Nb, varying in the content of Mo is presented as an offer for mining industry for replacement traditionally heat-treatable hardenability grades. The goal of the work is producing microstructure condition, which after controlled hot forging and direct heat treatment, involving quenching and self-tempering, are meant to provide good combination of mechanical properties, such as TYS 800 MPa, UTS 1050 MPa, elongation to fracture at least A5 15% and/or impact strength at room temperature KCV 60 J/cm2. Hardenability assessment and dilatometric examination allowed formulation of direct heat treatment guidelines, taking into consideration fields of temperature and strain in a typical hot forging process, estimated numerically, with the use of plastometric tests results, as well as the use of unique cooling cycles after forging. On the basis of numerical analysis of thermomechanical parameters and temperature progression, hot forging and direct cooling conditions were selected to achieve assumed structural components, morphology and dispersion of both grain and precipitates. For established heat transfer model and experimentally plotted cooling curves numerical analysis of direct cooling, enabled by definition of characteristic points of austenite transformation and CCT diagrams was conducted. The modeling aided with dilatometric characterization enabled prediction of transformation products distribution. The formulated conclusions were verified in the experimental sampling of forging, evaluating the applicability of designed combinations of chemical composition and cooling cycle for selected forged part for mining industry.

Temperature balanced hydrogen sensor system with coupled palladium nanowires

A temperature compensated hydrogen sensor was designed and made capable of detecting H2 within a broad range of 100–10.000ppm while compensating instantaneously for large (±25°C) temperature variations. Two related operational constraints have been simultaneously addressed: (1) Selective, and sensitive detection under large temperature changes, (2) Fast warning at low and increasing H2 levels. Accurate measurements of hydrogen concentrations were enabled by matching relevant time-constants. This was achieved with a microchip having two temperature coupled palladium nanowires. One of the H2 sensitive Pd nanowires was directly exposed to hydrogen, whilst the other nanowire was used as a temperature sensor and as a reference. A drop forging technique was used to passivate the second Pd wire against H2 sensing. Temperature effects could be substantially reduced with a digital signal processing algorithm. Measurements were done in a test chamber, enabling the hydrogen concentration to be controlled over short and long periods. An early response for H2 sensing is attainable in the order of 600 milliseconds and an accurate value for the absolute hydrogen concentration can be obtained within 15s.

Manufacturing process of plane rim from aluminium alloy

Purpose – The purpose of research was to work out manufacturing technology of plane rim from 2618A aluminium alloy based on hammer forging process. Design/methodology/approach – It was assumed that the manufacturing process consists of die hammer forging and machining. The first stage of the research works was based on designing of the forging process and on numerical simulations in which finite element method was used. On the basis of calculations results, analysis of deformation parameters in the drop forging was made and the rightness of the worked out technology was verified. The second stage of the research works concerned experiments conducted in industrial conditions. Forging dies were constructed and the forging process of a series of drop forgings was carried out. Next machining was done to obtain finished parts. Findings – The conducted research works on the forging process on hammer of the rim drop forging from 2618A aluminium alloy showed that the application of this technology allows for obta...

The Importance of Forging Line Modernization for Material Flow in Drop Forge

This contribution proposes an optimization of material flow by means of modernizing of forging lines - type induction furnace / crank forging press / trimming press. The basis of design of forging line treatment is placement of hydraulic shear machine for shearing of heated bar to semi-products before respective forging of forged pieces. This method helped to remove previous redundant workplace for semi-products preparation, which causes reduction of technologic operations and substantial decrease of material flow in die forge. Proposed variant of material flow optimization brings economic profit by means of reduction of production times and fuels costs intended for pallets transport. Given save will be interesting for die forges as it contains also calculation of logistical effect.

The Optimization of the Technological Parameters of Precision Die Forging of a Spur Gear Using a Computer Simulation

This paper deals with the optimization of the technological parameters of precision die forging in closed die in order to achieve a proper material flow in the die cavity for spur gears with a hub. This paper also studies the material flow in die cavity, effective plastic stress and strain, and temperature of drop forging using simulation software called SimufactForming. Forging cost is also compared between the closed and open die forging.

Wpływ jakości systemu pomiarowego na ocenę współczynników zdolności procesu

Among statistical instruments of quality Statistical Process Control (SPC) and Measurement Systems Analysis (MSA) take particular place. The proper quality of measurement data - verification and assurance of this quality are the task of MSA - guarantees an opportunity to carry out a solid SPC analysis supplying information about a process behavior. One of the principal tasks of SPC is estimation of capability of a process i.e. the assessment of process potential as for variability regarding expectations defined by specification limits. Data for analysis of a process capability are the results of measurements made by means of a determined measurement system. The variability of this measurement system must influence the results of capability assessment, however the measurement system adequate to control the process should guarantee that the impact is little enough to be omitted. The subject of the work is the analysis of influence of measurement system variability on evaluation of process capability indices. The mutual relations between process variability and measurement system variability present analytical relationships and experimental research given in the work. The aim of the tests was an assessment of a capability of the process of steel drop forgings' heat treatment relating to a hardness. The methodology demonstrated in the work is valid quality standards compatible (ISO 9000, ISO/TS 16949 etc.).

Automated Determination and On-Line Correction of Emissivity Coefficient in Controlled Cooling of Drop Forgings

The paper presents the methodology of determination of emissivity coefficient of steel in the direct cooling temperature range, which allow self-definition of this parameter in automated temperature control system used for direct cooling of drop-forged parts. Based on the actual temperature of the surface of the workpiece, the system automatically adjusts the velocity of fan-forced air to produce desired cooling rate and course of cooling curves. To enable automatic correction of cooling rate, the system must rely on exact remote temperature measurements. This is conditioned by correct definition of emissivity in pyrometer gauge system. Traditionally, pyrometers use presets of a constant value, selected as to get optimum consistency for the temperature range concerned. As the emissivity is time-dependent, the idea of the approach presented in the paper is to use time dependent characteristics, to attain the minimum discrepancy between actual and measured values during the whole cooling cycle.