Development of an innovative lightweight piston through process combination “casting – forging”

Krüger, Lutz; Jentsch, E.; Brunke, L.; Keßler, A.; Wolf, Gotthard; Lehnert, Tim; Schubert, Nadine; Wagner, A.; Landgrebe, Dirk

doi:10.1016/j.promfg.2018.12.061

Cited by 17 publications

(8 citation statements)

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“…A higher product quality is associated with a more favorable structure and high smoothness of the surface. This translates into improved tensile and functional properties when compared with products manufactured by the mechanical processing of castings [ 39 , 40 , 41 , 42 , 43 , 44 ]; Possibility of forming connecting rods from less ductile alloys possessing better tensile properties. The use of a shaped, cast preform without metal forming will have a positive effect on the flow kinematics and deformability of the material during forging [ 45 , 46 , 47 , 48 ]; Ecofriendliness of the novel process.…”

Section: Discussionmentioning

confidence: 99%

The New Technology of Die Forging of Automotive Connecting Rods from EN AB-71100 Aluminium Alloy Cast Preforms

Dziubińska

2023

Materials

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This article presents a new technology for forming automotive connecting rod forgings by means of die forging from cast performs from EN AB-71100 (EN AB-AlZn10Si8Mg) aluminum alloy. A premise was made that the production process would be carried out on forging presses. The process of forming connecting rod forgings was analyzed considering different deformation rates related to the type of machine used: a crank press and a screw press. The billet in the form of in-house designed, shaped preforms cast into sand molds with two variants of geometry was used in the process. The numerical analysis of the new process was carried out on the basis of the finite element method using Deform 3D, the simulation software for metal forming. The simulations were conducted in the spatial deformation conditions, considering the full thermomechanical analysis. Based on the simulations, certain important findings concerning the novel process were acquired, including the distribution of stress, deformation, temperatures, cracking criterion and energy parameters. The results of numerical tests confirmed the possibility of producing defect-free forgings of connecting rods from EN AB-71100 aluminum alloy on forging presses by means of the proposed technology. The proposed process of forging using crank and screw presses was verified in the course of tests conducted in industrial conditions. The properly formed connecting rod forgings were subjected to quality tests in terms of their structure and mechanical properties.

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Section: Discussionmentioning

confidence: 99%

The New Technology of Die Forging of Automotive Connecting Rods from EN AB-71100 Aluminium Alloy Cast Preforms

Dziubińska

2023

Materials

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“…A heat transfer coefficient of 4,5 kW/m 2 K between the formed material and tools was assumed, and 0,03 kW/m 2 K between the surroundings and the material [30]. In the calculations, a model of constant friction was adopted, in which the friction factor corresponding to the contact conditions between magnesium alloy and steel with graphite grease lubrication is µ = 0,24 [17]. For the hydraulic press, the speed of movement of the upper die was assumed to be 10 mm/s.…”

Section: Reasearch Medhodologymentioning

confidence: 99%

“…The forging technology allows for the final forming of the forgings and the improvement of its strength parameters. In specialist literature the descriptions of such production can be found, for example, of flanges [15], suspension arms [16] or pistons [17] with the use of various types of material, such as magnesium alloys AZ70 [18] or steel [19,20].…”

Section: Introductionmentioning

confidence: 99%

Numerical Analysis of the New Forming Process of the Aircraft Bracket Forging Made of AZ91 Alloy at Different Rates of Deformation

Dziubińska

Surdacki

2022

Teh. vjesn.

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The article presents the results of numerical simulations of the new forging process of the aircraft bracket forging at different deformation rates related to the type of machine used: a hydraulic press, a screw press and a drop forging hammer. The billet of shaped preforms from AZ91 alloy with two different geometries was used for the process. It was assumed that forging a bracket from an unformed, shaped preform will have a positive effect on the kinematics of the flow and on the deformation capability of AZ91 magnesium alloy, and will reduce the number of operations necessary to obtain the correct item. The numerical analysis of the new process was carried out with FEM, using the software Deform 3D. Based on the simulation, the important information about the process was obtained, that is the distribution of stress, deformation, temperatures, cracking and force parameters. The obtained results of numerical tests confirmed the possibility of producing the correct aircraft brackets forgings from AZ91 magnesium alloys with the proposed technology.

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“…Experiments are conducted at different pressures of fuel injection and the emission, combustion and performance were measured and evaluated. Alloys based on aluminium were extensile used for fabrication of various automotive and aerospace parts, due to their high formability, stiffness and specific strength [10][11]. Yet, both aluminium at its different alloys hold deprived resistance to wear, which directly affects the component's lifetime and performance especially in fatigue loaded components such as pistons, compressor blades etc., [12][13].…”

Section: Introductionmentioning

confidence: 99%

Investigation on engine performance test on compression ignition engine with hybrid metal matrix composite piston

Saminathan

Lakshmipathy

2022

THERM SCI

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The increase in demand and introduction of stringent emission regulations resulted in the need to develop and implement innovative technologies towards improving the emission and performance characteristics of compression ignition engines. A hybrid metal matrix composite piston (HMMC) of Al7075 reinforced with 6% of 100 ?m Silicon Carbide (SiC) and 4% of 100 ?m Aluminium oxide (Al2O3) was fabricated. The HMMC piston was mounted on a compression ignition (CI) four stroke single-cylinder constant speed engine and the test was carried out with eddy current dynamometer attached with computerized data acquisition system. This paper is focused on the study of performance of Al7075-SiC-Alumina composite piston for compression ignition engine application. Experimental investigations were performed at injection pressure of 200 and 220 bar on both standard piston and HMMC piston and analysed the performance, combustion and emission behaviour of CI engine. From the results it was found that the HMMC piston exhibits an improved efficiency and thereby improving the lifetime of the engine. Though a little compromise in performance and emissions has been accepted, the implementation of HMMC pistons will reduce the carbon foot print of running an internal combustion engine.

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Development of an innovative lightweight piston through process combination “casting – forging”

Cited by 17 publications

References 0 publications

The New Technology of Die Forging of Automotive Connecting Rods from EN AB-71100 Aluminium Alloy Cast Preforms

The New Technology of Die Forging of Automotive Connecting Rods from EN AB-71100 Aluminium Alloy Cast Preforms

Numerical Analysis of the New Forming Process of the Aircraft Bracket Forging Made of AZ91 Alloy at Different Rates of Deformation

Investigation on engine performance test on compression ignition engine with hybrid metal matrix composite piston

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