“…Figure 2.Thermograms with temperature distributions on top punches used in the process of forging a disk: (a) tool lubrication cycle – the temperature at the marked point is 97 ℃, (b) 3 s after the end of lubrication – temperature increases by over 100 ℃, (c) just after the forging process – about 1 s after deformation and (d) temperature field on the analyzed punch at the time of forging (contact) determined by numerical modelling. 12 Figure 3.A view of: (a) the die temperature change during forging with marked most frequently occurring process disturbances and (b) transfer of forgings on the transfer press – thermocouple mounting into the set of lower tool. 54 …”
Section: A Review Of the Research Of The Lubricant Supply Methods And mentioning
confidence: 99%
“…Thermograms with temperature distributions on top punches used in the process of forging a disk: (a) tool lubrication cycle – the temperature at the marked point is 97 ℃, (b) 3 s after the end of lubrication – temperature increases by over 100 ℃, (c) just after the forging process – about 1 s after deformation and (d) temperature field on the analyzed punch at the time of forging (contact) determined by numerical modelling. 12 …”
Section: A Review Of the Research Of The Lubricant Supply Methods And mentioning
confidence: 99%
“…8,9 The mutual, quantitative proportions of individual destructive mechanisms affecting the forging tools vary greatly and mainly depend on the operational conditions present during the forging process. [10][11][12][13] In the case of typical carbon steel, where the yield point is in the range of 200-400 MPa, the material can be forged both cold, hot and hot. However, for steels with a yield point above 500 MPa, die forging processes are carried out at a temperature above 1000 C.The industry also uses precision forging of steel (temperature of the input material is about 900 C), in which after the semihot (called also warm) forming operations, the final cold finishing operation is applied.…”
This article presents selected aspects of lubricant application, as well as lubrication methods and devices in the context of forging tool durability and accessories used in die forging processes at elevated temperatures. The properties and applications of the currently used lubricating and cooling agents in selected industrial forging processes were analyzed. The authors’ original studies on the influence of lubricant application, dose size, time and feed direction as well as other factors affecting tribological conditions are also presented. A review of lubricating and cooling systems and devices is provided, as well as a lubricating device built on the basis of the authors’ knowledge and experience is presented. The developed system, implemented into an industrial process, makes it possible to select and maintain its optimal tribological conditions through the control of the size and frequency of the administered lubricant dose. It may be an alternative to the manual lubricant application method, where human error is a factor, or to fully automated, but expensive, lubrication systems.
“…Figure 2.Thermograms with temperature distributions on top punches used in the process of forging a disk: (a) tool lubrication cycle – the temperature at the marked point is 97 ℃, (b) 3 s after the end of lubrication – temperature increases by over 100 ℃, (c) just after the forging process – about 1 s after deformation and (d) temperature field on the analyzed punch at the time of forging (contact) determined by numerical modelling. 12 Figure 3.A view of: (a) the die temperature change during forging with marked most frequently occurring process disturbances and (b) transfer of forgings on the transfer press – thermocouple mounting into the set of lower tool. 54 …”
Section: A Review Of the Research Of The Lubricant Supply Methods And mentioning
confidence: 99%
“…Thermograms with temperature distributions on top punches used in the process of forging a disk: (a) tool lubrication cycle – the temperature at the marked point is 97 ℃, (b) 3 s after the end of lubrication – temperature increases by over 100 ℃, (c) just after the forging process – about 1 s after deformation and (d) temperature field on the analyzed punch at the time of forging (contact) determined by numerical modelling. 12 …”
Section: A Review Of the Research Of The Lubricant Supply Methods And mentioning
confidence: 99%
“…8,9 The mutual, quantitative proportions of individual destructive mechanisms affecting the forging tools vary greatly and mainly depend on the operational conditions present during the forging process. [10][11][12][13] In the case of typical carbon steel, where the yield point is in the range of 200-400 MPa, the material can be forged both cold, hot and hot. However, for steels with a yield point above 500 MPa, die forging processes are carried out at a temperature above 1000 C.The industry also uses precision forging of steel (temperature of the input material is about 900 C), in which after the semihot (called also warm) forming operations, the final cold finishing operation is applied.…”
This article presents selected aspects of lubricant application, as well as lubrication methods and devices in the context of forging tool durability and accessories used in die forging processes at elevated temperatures. The properties and applications of the currently used lubricating and cooling agents in selected industrial forging processes were analyzed. The authors’ original studies on the influence of lubricant application, dose size, time and feed direction as well as other factors affecting tribological conditions are also presented. A review of lubricating and cooling systems and devices is provided, as well as a lubricating device built on the basis of the authors’ knowledge and experience is presented. The developed system, implemented into an industrial process, makes it possible to select and maintain its optimal tribological conditions through the control of the size and frequency of the administered lubricant dose. It may be an alternative to the manual lubricant application method, where human error is a factor, or to fully automated, but expensive, lubrication systems.
“…[13,14] analyze the progressing wear of forging tools and forging defects by monitoring volume changes in the manufactured workpieces using 3D mesh reconstruction. In addition, the use of optical scanners allows the integration of numerical methods (such as Finite Element Analysis) in the dimensional inspection pipeline to quantify the thermal and structural damage of the forging tool [1,3]. Other dimensional inspection methods in warm forming include computed tomography [7,15], thermographic assessment [16], ultrasonic assessment [17], liquid penetrant testing [18], among others.…”
Section: Off-line Dimensional Inspection In Warm-die Manufacturingmentioning
confidence: 99%
“…In the context of warm forming of motorcar parts, current production lines of stub axles process around 1200 pieces per hour. The tools used to form these parts are constantly subjected to high structural and thermal stresses [1][2][3], requiring continuous monitoring and dimensional assessment of the produced parts for process and quality control.…”
Industrial dimensional assessment presents instances in which early control is exerted among "warm" (approx. 600 • C) pieces. Early control saves resources, as defective processes are timely stopped and corrected. Existing literature is devoid of dimensional assessment on warm workpieces. In response to this absence, this manuscript presents the implementation and results of an optical system which performs in-line dimensional inspection of revolution warm workpieces singled out from the (forming) process. Our system can automatically measure, in less than 60 s, the circular runout of warm revolution workpieces. Such a delay would be 20 times longer if cool-downs were required. Off-line comparison of the runout of T-temperature workpieces (27 • C ≤ T ≤ 560 • C) shows a maximum difference of 0.1 mm with respect to standard CMM (Coordinate Measurement Machine) runout of cold workpieces (27 • C), for workpieces as long as 160 mm. Such a difference is acceptable for the forging process in which the system is deployed. The test results show no correlation between the temperature and the runout of the workpiece at such level of uncertainty. A prior-to-operation Analysis of Variance (ANOVA) test validates the repeatability and reproducibility (R&R) of our measurement system. In-line assessment of warm workpieces fills a gap in manufacturing processes where early detection of dimensional misfits compensates for the precision loss of the vision system. The integrated in-line system reduces the number of defective workpieces by 95%. matrix orientation in the forging process is crucial since a severe misalignment between the punch press and the forming matrix axes disables the posterior machining process, resulting in a scrapped part. The circular runout [4] of the forged revolution workpiece indicates the deviation between the punch orientation and the forming matrix axis.Standard tools for dimensional assessment of these workpieces rely on contact between the probe and the measured workpiece. Such is the case of Coordinate Measurement Machines (CMMs), which provide highly accurate measurements [5]. However, dimensional assessment with standard CMMs (and contact methods in general) is not convenient due to (1) the high temperatures directly affect (or even damage) the probe and, (2) long measurement times for the cooled-down workpieces. Consequently, a delay of nearly 20 min between the production of a single part and its dimensional assessment (including its cooling down, transportation to the metrology office and measuring times) arises. Such time delay translates into an uncertainty in the quality control process of approximately 400 potential defective workpieces (worst case scenario) for each measurement.This manuscript presents an optical (i.e., contact-avoiding) system for in-line dimensional assessment of warm forming of revolution workpieces. Our system can continuously measure the circular runout of the parts at around 600 • C in less than 60 s per part. Results from experiments conducted in this manuscript show ...
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