Recent development trends in metal forming

Gronostajski, Z.; Pater, Z.; Madej, Łukasz; Gontarz, A.; Lisiecki, Łukasz; Łukaszek-Sołek, A.; Łuksza, J.; Mróz, S.; Muskalski, Z.; Muzykiewicz, W.; Pietrzyk, M.; Śliwa, R. E.; Tomczak, J.; Wiewiórowska, S.; Winiarski, Grzegorz; Zasadziński, J.; Ziółkiewicz, S.

doi:10.1016/j.acme.2019.04.005

Cited by 130 publications

(81 citation statements)

References 155 publications

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“…The Lagrangian finite element code MSC.Marc 2017 was used to investigate the considered factors, as illustrated in Figure 3. The following assumptions were made: (1) 2D axisymmetric conditions, (2) no heat transfer to the tools, and (3) using the power-law material model. An axisymmetric model was set up to simulate the extrusion process.…”

Section: Finite Element Simulationmentioning

confidence: 99%

“…Both of the calculated values from (1), (2), and the actual coatings development costs would provide the tool design guidelines for the micro-extrusion engineers.…”

Section: Combined Friction Modelmentioning

confidence: 99%

“…New products, solutions, and processes must be developed in order to meet such high demands. Aluminum extrusion is one of the vital metal forming processes that provide net-shape and mass-production benefits [2]. The recent trend in miniaturization has shown that metallic micro parts (mechanical micro connector pins, miniature contact springs, and electronic parts with micro features) are growing in automobiles and electronics [3].…”

Section: Introductionmentioning

confidence: 99%

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Effects of Tool Coatings on Energy Consumption in Micro-Extrusion of Aluminum Alloy 6063

et al. 2020

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The tool wear rate and energy consumption were typically unknown in micro-extrusion, which made it difficult to optimize the tool design for both the final part quality and production cost. This study investigated the effects of tool coatings on energy consumption in the micro-extrusion of aluminum alloy 6063. Three main factors were considered in this study: (1) tool coating types, (2) bearing length, and (3) extrusion ratio. The micro-extrusion finite element simulation model was developed and validated with the micro-extrusion experiment. The results showed that increasing bearing lengths led to the increase in tool wear rate and energy consumption for all the coating types. The decreasing coefficient of friction values of the tool-billet interface led to a decrease in energy consumption. High hardness values of the tool surface and low bearing lengths helped increase tool life. Low values of coefficient of friction and bearing lengths helped decrease energy consumption.

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Section: Finite Element Simulationmentioning

confidence: 99%

“…Both of the calculated values from (1), (2), and the actual coatings development costs would provide the tool design guidelines for the micro-extrusion engineers.…”

Section: Combined Friction Modelmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Effects of Tool Coatings on Energy Consumption in Micro-Extrusion of Aluminum Alloy 6063

et al. 2020

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“…The lifetime of tools applied in industrial manufacturing processes is one of the primary factors deciding the efficiency of a given production process [1]. Metal forming processes, including hot die forging processes, where tools are very complicated and expensive to make and tool costs may even reach up to 30% of total production costs, are a special group of manufacturing processes characterized by low tool lifetime [2].…”

Section: Introductionmentioning

confidence: 99%

The application of a new, innovative, hybrid technology combining hardfacing and nitriding to increase the durability of forging tools

Kaszuba

2020

Archiv.Civ.Mech.Eng

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The article deals with the wear of forging tools used in hot forging processes. The research presented in the work includes analysis of tool life used in a selected industrial hot die forging process. Multiple treatment variants were used to increase wear resistance, including thermo-chemical treatment (nitriding), welding methods (surfacing) and an innovative new hybrid technology combining surfacing and nitriding. First of all, the research focused on determining the impact of the phase structure of the nitrided layers used and the surfacing layer on resistance to destructive factors occurring in the analyzed process. Next, hybrid treated tools combining surfacing and nitriding were also subjected to operational tests. Each of the tools analyzed in this work was operated until it was withdrawn due to excessive wear, and then subjected to comprehensive analysis. The tests of tools after operation included: surface scanning to determine the amount of wear of the analyzed tools after work, microhardness measurement, and microscopic tests. A detailed analysis of changes in the surface layer of tools in selected areas was made using a scanning microscope. The aim of the study was to assess the effectiveness of the hybrid surface treatment process used to increase the wear resistance of the surface layer of tools and thereby improve the durability of the forged tools analyzed. The obtained research results indicate a beneficial effect of using the new technology resulting in 300% increase in the durability of the analyzed tools. The effect of improving durability confirmed by obtained results arises from the use of hybrid layers, which are more resistant to abrasive wear and to cracking due to thermo-mechanical fatigue. Moreover, the study shows that nitriding may have a beneficial influence on improving the lifetime of forging tools, under the condition that the nitrided layer has an α diffusive layer structure, without a larger amount of γ’ and ε nitride precipitates.

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“…To increase the manufacturing efficiency and decrease energy consumption of the production process for railway axles, studies were undertaken to investigate the possibility of manufacturing these parts by rolling methods. Cross-wedge rolling (CWR), which is widely used for manufacturing stepped axles and shafts for the automotive industry [4,5], is a promising technique in this respect. What poses problems, however, is the axle size, as it directly affects the dimensions of machines and tools.…”

Section: Introductionmentioning

confidence: 99%

A Comparative Analysis of Forming Railway Axles in 3- and 4-Roll Rolling Mills

Pater

2020

Materials

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The paper presents a comparative analysis of skew rolling in 3- and 4-roll CNC rolling mills. The analysis is performed using the FEM-based commercial simulation software Simufact.Forming. The formation of both solid and hollow railway axles is analyzed. Distributions of effective strain, temperature and damage criterion in rolled axles are determined, and loads and torques acting on the tools during rolling are estimated. An innovative concept of calibrating hollow axles by the rotary compression technique developed at the Lublin University of Technology is presented. Experimental tests of rolling solid axles in a 3-roll rolling mill (in a scale of 1:5) are performed, and basic force parameters of the rolling process are measured. Numerical and experimental loads and torques show a high agreement in terms of both quality and quantity.

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Recent development trends in metal forming

Cited by 130 publications

References 155 publications

Effects of Tool Coatings on Energy Consumption in Micro-Extrusion of Aluminum Alloy 6063

Effects of Tool Coatings on Energy Consumption in Micro-Extrusion of Aluminum Alloy 6063

The application of a new, innovative, hybrid technology combining hardfacing and nitriding to increase the durability of forging tools

A Comparative Analysis of Forming Railway Axles in 3- and 4-Roll Rolling Mills

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