Analysis of forging defects for selected industrial die forging processes

Hawryluk, Marek; Jakubik, J.

doi:10.1016/j.engfailanal.2015.11.008

Cited by 89 publications

(49 citation statements)

References 10 publications

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“…Bar shearing is a necessary step that precedes many forging processes [32,33]. Finite element analysis of bar shearing contributes to improve the quality of the sheared billets and plays thus an important role to optimize the subsequent processes by reducing defects like underfill and folds [34]. The most decisive factors determining the aspect of the sheared surface are shearing clearance, shearing speed, blade edge radius, draft angle and billet temperature [35].…”

Section: Shearing Simulationmentioning

confidence: 99%

Modeling of the ductile damage – Application for bar shearing

Moakhar

Hentati

Barkallah

et al. 2019

Materialwissenschaft Werkst

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The finite element method is becoming a reliable tool for designing manufacturing processes. Even in bar shearing, which is a basic operation in the metalworking industry, the finite element method is increasingly employed for the optimization of the process. Ductile damage modeling is crucial thereby. Recent experimental investigations have shown that, in particular, triaxiality and temperature must be considered in the constitutive description of damage in the shear zone. In this context, the Hooputra's criterion is in this work applied for the numerical simulation of shearing taking account of different stress states and temperatures. The parameterization of the model is based on wide experimental investigations. Characterization tests on smooth and notched cylindrical specimens as well as on flat shear specimens are carried out. The selected material for this investigation is the aluminum alloy AW6082. Subsequently, the numerical calculation of shearing is performed. By comparing the simulation results with data from experimental shearing, the importance of the consideration of the temperature gradients and the different triaxiality values in the shear zone is proven. Keywords: Damage model / temperature / triaxiality / finite element method / bar shearing / fracture characteristic tests Die Finite-Elemente-Methode (FEM) ist heutzutage ein zuverlässiges Tool bei der Auslegung von Fertigungsverfahren. Auch beim Knüppelscheren, das eine entscheidende Operation in der Metallverarbeitungsindustrie darstellt, wird die FEM für die Optimierung dieses Prozesses immer häufiger eingesetzt. Dabei spielt die Modellierung der duktilen Schädigung eine wichtige Rolle. Neue experimentelle Untersuchungen haben gezeigt, dass insbesondere die Triaxialität und die Temperatur bei der konstitutiven Beschreibung der Schädigung in der Scherzone zu berücksichtigen sind. In diesem Sinne wird im Rahmen dieser Arbeit das Hooputra-Kriterium unter Berücksichtigung unterschiedlicher Spannungszustände und Temperaturen in der numerischen Abbildung des Knüppelscherens angewendet. Die Parametrierung des Modells erfolge anhand umfangreicher experimenteller Untersuchungen. Dabei werden Versagensversuche an vollen und taillierten zylin-

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Section: Shearing Simulationmentioning

confidence: 99%

Modeling of the ductile damage – Application for bar shearing

Moakhar

Hentati

Barkallah

et al. 2019

Materialwissenschaft Werkst

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“…In the industrial coordinate metrology, new trends are observed, connected with the use of non-contact measurement techniques. It is possible owing to the continuous improvement of measurement techniques and introduction of new devices and measurement methods, such as fast scanning methods combined with CAD/CAM/FEM [9,14,18,22,27,28]. It creates the necessity of applying numerical 3D models to the determination of nominal values during measurements.…”

Section: Introductionmentioning

confidence: 99%

Development of a Method for Tool Wear Analysis Using 3D Scanning

Hawryluk¹,

Ziemba²,

Dworzak³

2017

Metrology and Measurement Systems

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The paper deals with evaluation of a 3D scanning method elaborated by the authors, by applying it to the analysis of the wear of forging tools. The 3D scanning method in the first place consists in the application of scanning to the analysis of changes in geometry of a forging tool by way of comparing the images of a worn tool with a CAD model or an image of a new tool. The method was evaluated in the context of the important measurement problems resulting from the extreme conditions present during the industrial hot forging processes. The method was used to evaluate wear of tools with an increasing wear degree, which made it possible to determine the wear characteristics in a function of the number of produced forgings. The following stage was the use it for a direct control of the quality and geometry changes of forging tools (without their disassembly) by way of a direct measurement of the geometry of periodically collected forgings (indirect method based on forgings). The final part of the study points to the advantages and disadvantages of the elaborated method as well as the potential directions of its further development.Keywords: 3D scanning, measurements and volumetric analysis of tools wear, improve a durability of forging tools.

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“…Tool durability is a complex issue, and tool wear significantly lowers the quality of the produced forgings. This subjects were widely described by authors in following works [23][24][25]. In the work [24], the author concentrates on selected methods, which provide the highest effectiveness in the improvement of the forging tool life, used in the industrial processes of die forging, based on own research and experiments realized in cooperation with the forging industry.…”

Section: Introductionmentioning

confidence: 99%

“…The most frequent forging defects caused by wear are errors in the filling of the die impression, that is: incomplete forging, laps, burrs, bends, scratches, delaminations, micro-and macro-cracks, etc. This, in turn, affects the functionality of the final product created from the forging [25].…”

Section: Introductionmentioning

confidence: 99%

The Use of 3D Scanning Methods to Evaluate the Hybrid Layer Used in Forging Tools in Order to Improve their Durability

Gronostajski¹,

Hawryluk²,

Kaszuba³

et al. 2017

Archives of Metallurgy and Materials

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This study is focused on tools used in the industrial process of hot forging of a front wheel forging (gear wheel) manufactured for the automotive industry. Five different variants were applied for the tools: 3 die inserts were coated with three different hybrid layers (PN + PVD type), i.e. AlCrTiN, AlCrTiSiN and CrN, one insert was only nitrided, and one was pad welded, to improve tool durability. The tool wear was analysed and represented by the material degradation on the working surface, based on the 3D scanning and the material growth of the periodically collected forgings. Additionally, the scanned tools were divided into two areas, in which it was found, based on the analysis, that various degradation mechanisms are predominant. Microstructural tests and hardness measurements of the analyzed tools were also performed. Based on the results, it was found that, in the central part of the die insert, thermo-mechanical fatigue, abrasive wear and plastic deformation occurred, while in the area of the bridge insert, only abrasive wear could be observed. For these areas, the loss of material was determined separately. It was established that the use of the GN+CrN and GN+AlCrTiN hybrid layers on forging tools improves their durability, while the best results in the central area were observed on the tool with the GN+CrN layer, which is the most resistant to thermo-mechanical fatigue. In the second analyzed area, good wear resistance occurred on GN+CrN, GN+AlCrTiN and pad welded inserts, for which, together with the increase of the forging number, a proportional, slight growth of the loss of material occurred.

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Analysis of forging defects for selected industrial die forging processes

Cited by 89 publications

References 10 publications

Modeling of the ductile damage – Application for bar shearing

Modeling of the ductile damage – Application for bar shearing

Development of a Method for Tool Wear Analysis Using 3D Scanning

The Use of 3D Scanning Methods to Evaluate the Hybrid Layer Used in Forging Tools in Order to Improve their Durability

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