Theoretical and Experimental Study on the Effect of Selected Parameters in a New Method of Extrusion with a Movable Sleeve

Winiarski, Grzegorz

doi:10.3390/ma15134585

Cited by 3 publications

(3 citation statements)

References 56 publications

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“…The forming process is a combination of extrusion and upsetting. More details regarding the evolution of the idea of elaborated metal forming technology are presented in previous papers [30,[32][33][34]. The current study physically modeled the metal forming process in laboratory conditions using a 1:2.5 scale of die tools.…”

Section: Forging Of the Hollow Steel Component With An Outer Flangementioning

confidence: 99%

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Microstructure and Hardness of Cold Forged 42CrMo4 Steel Hollow Component with the Outer Flange

Szala¹,

Winiarski²,

Bulzak³

et al. 2022

Adv. Sci. Technol. Res. J.

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For decades, steel has been a crucial structural material. Mainly low-alloy steel grade 42CrMo4 is utilized for manufacturing forgings. This paper investigates the microstructure and hardness development of the 42CrMo4 steel hollow component with an outer flange. The component has been formed via cold forging in combination with extrusion and upsetting technologies. Prior to forming, the workpiece was annealed to obtain hardness at the level of 181±9 HV0.3. The FEM analysis reveals the areas that undergo higher stress and strain. The flow lines macrostructure and microstructure of hollow parts were investigated using light optical microscopy (LOM) and scanning electron microscopy (SEM) equipped with EDS. Vickers hardness allows identifying the work hardening of the crucial element areas. The microstructure consists of ferrite matrix and semispherical carbides. Laboratory studies confirm appropriate flow lines arrangement, which corresponds well to those shown by FEM computer simulations. The highest hardness at the level of 293±7 HV0.3 was identified in the flange area, where the material shows a higher distribution of effective strain revealed by FEM. Cold metal forming results in work-hardening of the steel. The work hardening ranges up to 1.62 of the initial 42CrMo4 steel hardness. The metal forming process did not affect the microstructural uniformity of the flanged hollow part. The final outer flange component presents high quality and is free from plastic deformation nonuniformities.

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Section: Forging Of the Hollow Steel Component With An Outer Flangementioning

confidence: 99%

“…The innovative technology relies on cold forging in combination with extrusion and upsetting methods. The process was investigated via numerical simulations and positively verified experimentally on the model aluminum alloy [32]. The elaborated novel metal forming process is dedicated to manufacturing elements of 42CrMo4 steel.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Hardness of Cold Forged 42CrMo4 Steel Hollow Component with the Outer Flange

Szala¹,

Winiarski²,

Bulzak³

et al. 2022

Adv. Sci. Technol. Res. J.

Self Cite

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“…In closed-die extrusion, the flange height could be several times greater than the workpiece wall thickness, which allowed for multi-step flange forming [24,25]. In semi-open die extrusion, the achievable flange height was constrained by a potential loss of workpiece/mandrel contact in the zone outside the die impression as well as flank inclination [26,27].…”

Section: Introductionmentioning

confidence: 99%

Analysis of a New Process for Forming Two Flanges Simultaneously in a Hollow Part by Extrusion with Two Moving Dies

Winiarski,

Gontarz,

Skrzat

et al. 2024

Metals

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This paper presents a new method for forming flanges in hollow parts. The process consists of an extrusion with two dies that move in an opposite direction to that of the punches. This particular kinematics of the tools makes it possible to form two flanges simultaneously in a single tool pass. The proposed method was investigated using a tube made of steel 42CrMo4. It was assumed that the extrusion would be conducted as a cold forming process at ambient temperature. Different diameters and heights of the impression made in the top and bottom dies were used. It was demonstrated that the main failure mode of the proposed technique was an unintended increase in the inside the diameter of the workpiece in the flange zone. The results showed that the above parameters had a key impact on the achievable maximum flange diameters and heights.

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A Study Utilizing Numerical Simulation and Experimental Analysis to Predict and Optimize Flange-Forming Force in Open-Die Forging of C45 Billet Tubes

2023

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Open-die forging holds a pivotal role in shaping machine parts within industrial applications. This study focuses on the assessment of stress–strain curves for C45 material at different elevated temperatures and strain rates through numerical simulations employing the finite element method (FEM). Specifically, the research investigates how the flow curve of materials at elevated temperatures and individual strain rates impacts the forming force during the flange forming of C45 billet tubes. By comparing the simulation results with experimental data on the flange-forming force, this study observes that optimal outcomes arise when considering both elevated temperature and strain rates in the flow curve of materials. The study then conducts simulations for C45 billet tubes with varying upsetting ratios (H0/D0), (S0/D0), and the punch’s pitch angle (α), aiming to address optimization challenges related to the flange-forming force. Consequently, a mathematical model is developed to represent the relationship between the flange-forming force and geometric parameters (H0/D0, S0/D0, and α). This model accurately predicts the forming force under various flange-forming conditions, demonstrating high precision with a maximum error of 4.26% compared with the experimental results. This study significantly contributes to the advancement of flange-forming technology in open-die forging through numerical simulation, enabling the optimization of the flange-forming force and the selection of appropriate equipment. These findings pave the way for more effective and efficient industrial processes, fostering innovation and progress in the field.

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Theoretical and Experimental Study on the Effect of Selected Parameters in a New Method of Extrusion with a Movable Sleeve

Cited by 3 publications

References 56 publications

Microstructure and Hardness of Cold Forged 42CrMo4 Steel Hollow Component with the Outer Flange

Microstructure and Hardness of Cold Forged 42CrMo4 Steel Hollow Component with the Outer Flange

Analysis of a New Process for Forming Two Flanges Simultaneously in a Hollow Part by Extrusion with Two Moving Dies

A Study Utilizing Numerical Simulation and Experimental Analysis to Predict and Optimize Flange-Forming Force in Open-Die Forging of C45 Billet Tubes

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