Lubrication in hot die forging processes

Hawryluk, Marek; Ziemba, Jacek

doi:10.1177/1350650118784728

Cited by 10 publications

(11 citation statements)

References 38 publications

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“…In the event of a downtime or technological break, the tools are reheated and the temperature of the tools is measured with a pyrometer before the process is started again. In the industrial forging process for lubrication, a fully automatic cooling and lubricating device developed by the authors was used, which was demonstrated in several studies [34][35][36]. Such devices ensure stable and repeatable lubrication conditions.…”

Section: Analysis Of Industrial Forging Processmentioning

confidence: 99%

Analysis of the Industrial Process of Producing a Hub Forging Used in Motorcar Power Transmission Systems—A Case Study

Hawryluk

Rychlik²,

Więcław

et al. 2021

JMMP

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The article refers to an analysis of the multi-operation process of manufacturing a hub type forging used to transmit power in motorcar gear boxes, by way of die forging on a crank press. The investigations were performed in order to improve the currently realized production technology, mainly with the use of numerical simulations. Through the determination of the key parameters/quantities during forging, which are difficult to determine directly during the industrial process, an in-depth and complex analysis was performed by way of FE (Finite Element) modelling. A thermomechanical model of producing a hub forging with deformable tools was developed with the use of the Qform 9.0.9 software. For the elaboration and construction of the forging tool CAD (Computer Aided Design) models, the Catia V5R20 program was applied. The results of the performed numerical modelling made it possible to determine the material flow and the properness of the filling of impressions, as well as the temperature field distributions and plastic deformations in the forging; it was also possible to detect the forging defects often observed in the industrial process. On this basis, the changes in the process were determined, which enabled an improvement of the presently realized technology and the obtaining of proper forgings, both in respect of quality and dimensions and shape.

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Section: Analysis Of Industrial Forging Processmentioning

confidence: 99%

Analysis of the Industrial Process of Producing a Hub Forging Used in Motorcar Power Transmission Systems—A Case Study

Hawryluk

Rychlik²,

Więcław

et al. 2021

JMMP

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“…Distance between preforming die and workpiece equation: C = 308.7-1.706 D − 2.694 L − 0.491 F + 0.01118 D 2 + 0.00612 L 2 + 0.00780 F 2 + 0.00450 DL − 0.00525 DF + 0.00330 LF (7) The variance analysis of the distance between the preforming die and the workpiece is shown in Table 4.…”

Section: Optimized Die Of the Cdz Of Damping Wallsmentioning

confidence: 99%

“…The molding equipment in the hot forging process will be due to friction and wear, thermal fatigue, plastic deformation and brittle cracks of the mold [1]. If the forging die is deformed, its surface combination and density will change [7][8][9]. The pressure per unit area and the friction of the contact surface, the hardness of the material and the quality of the forging will all affect the mechanical load of the forging.…”

Section: Introductionmentioning

confidence: 99%

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Optimization of Controllable Deformation Zone And Die Wear of Aluminum Crown Forgings For Shock Absorber Assembly

Shih

et al. 2021

Preprint

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In this research, numerical analysis, response surface method (RSM) and experiments are used to investigate and verify the hot forging process for manufacturing aluminum crown forgings for shock absorber assembly. First, establish the computer aided design (CAD) model of the die and the billet, and simulate it from the finite element method (FEM). Second, a new preforming die was designed with a preformed dressing of controllable deformation zone (CDZ) by the CAD software. Third, numerical simulation was combined with RSM to optimize the processing parameters with the aim of minimizing the die wear while the integrity of forgings should be prioritized preserved. According to RSM, the billet size and preformed dressing of CDZ are important factors affecting the distance between die and workpiece (C). The optimal design factor of the preforming die: billet diameter (D), billet length (L) and flash design (F) are 40 mm, 205 mm and CDZ 1, respectively. Through the results of FEM, this study describes the distribution of microscopic grain flow lines are highly related to forming, stress, strain, and temperature as well as die design such as CDZ in preformed dressing. In order to accurately verify that the parameters analyzed by the RSM, both numerical analysis and physical experiments are carried out and optimal scheme exhibit reasonable consistency.

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“…Therefore, an intensive search is currently taking place to find new technological solutions dedicated to specific forging applications to provide optimal tribological conditions with relatively low financial outlays, while being reliable and easy to implement in die forging shops. For example, in [ 29 ], the authors reviewed modern commercial lubrication systems and presented their proprietary low-cost lubricating and cooling device, the use of which resulted in the reduced forging tool wear. In [ 30 ], the authors developed a lubricating device equipped with a peristaltic pump, which ensured the delivery of a constant dose of lubricant in the front wheel forging process.…”

Section: Introductionmentioning

confidence: 99%

The Impact of the Lubricant Dose on the Reduction of Wear Dies Used in the Forging Process of the Valve Forging

2021

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The paper presents the results of research on the influence of the settings of lubrication and cooling system parameters (solenoid valve opening time and lubricant feed pressure in terms of its quantity) in order to select the optimal lubricating conditions and thus reduce the wear of the dies used in the first forging operation of the valve forging made of high-nickel steel. Based on the observation of lubrication in the industrial process, it was found that a significant part of the lubricant fails to reach the die cavity, reaching the outside of it, which causes die wear due to seizure resulting from adhesion of the forging material to the tool surface as well as high lubricant consumption and dirt in the press chamber. The authors proposed their own mobile lubricating and cooling system, which allows for a wide range of adjustments and provided with automatic cleaning procedures of the entire system, unlike the fixed lubrication system used so far in the industrial process. First, tests were carried out in laboratory conditions to determine the highest wettability and the lubricant remaining inside the tool cavity. These tests determined the lubrication system parameter settings that ensured that the greatest amount of lubricant remains in the cold die cavity without the forging process. Then, to verify the obtained results, tests were carried out in the industrial process of hot die forging of valve forgings for short production runs of up to 500 forgings. The results were compared with the measurement of changes in the geometry of tools and forgings based on 3D scanning and surface topography analysis with the use of SEM (Scanning Electron Microscope). For the best results (the variant of the setting of the dose and the time of exposure to lubricant), the forging process was carried out with the use of a new tool up to the maximum service life.

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Lubrication in hot die forging processes

Cited by 10 publications

References 38 publications

Analysis of the Industrial Process of Producing a Hub Forging Used in Motorcar Power Transmission Systems—A Case Study

Analysis of the Industrial Process of Producing a Hub Forging Used in Motorcar Power Transmission Systems—A Case Study

Optimization of Controllable Deformation Zone And Die Wear of Aluminum Crown Forgings For Shock Absorber Assembly

The Impact of the Lubricant Dose on the Reduction of Wear Dies Used in the Forging Process of the Valve Forging

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