Numerical analysis of unconventional forging process of hollowed shaft from Ti-6Al-4V alloy

This paper presents theoretical analysis of unconventional forging process of hollowed shaft from Ti-6Al-4V alloy in a three-slide forging press. This method in comparison with other metal forming methods allows for obtaining of hollowed products. The designed process is verified theoretically by means of numerical simulations based on finite element method with assumption of 3D state of strain. The following factors are considered in the analysis: material flow kinematics, strain distribution, temperature distribution and force of process. On the basis of results, it is stated that the application of designed technology allows for obtaining of a product of assumed quality. A comparison is made between material consumption in analyzed process and material consumption in typical metal forming methods, also in used at present technology of shaft manufacturing by machining only. It is stated that the application of forging in the three-slide forging press allows for a considerable decrease of manufacturing costs due to material savings and decrease of labor consumption of operations at finishing.     

Investigation on Zener-Hollomon Parameter in the Warm-Hot Deformation Behavior of CF53

The warm-hot deformation behavior of CF53 steel was studied with hot compression tests at temperature of 1 123 ~1 273 K and strain rate of 0.1~20 s -1 . The activation energy for warm-hot deformation is 274.816 kJ/mol. The influences of Zener-Hollomon parameter, strain and grain size imposing on the flow stress were analyzed in the temperature range of warm-hot forging. Based on the creep theory and mathematic theory of statistics, mathematical models of flow stress were obtained. The results provide a scientific basis for controlling microstructure of forging process through Zener-Hollomon parameter.     

Forging penetration efficiency of steel H13 stepped shaft radial forging with GFM forging machine

The numerical thermal mechanical simulation of radial forging process of steel H13 stepped shaft with GFM (Gesellschaft fur Fertigungstechnik und Maschinenbau) forging machine was carried out by three-dimensional finite element code DEFORM 3D. According to the effective plastic strain, the mean stress and the mean plastic strain distribution of the radial forging, the forging penetration efficiency (FPE) was studied throughout each operation. The results show that the effective plastic strain in the center of the forging is always greater than zero for the desirable larger axial drawing velocity. The mean stress in the center of the workpiece is proposed to describe hydrostatic pressure in this paper. There is compressive strain layer beneath the surface of the workpiece to be found, while there is tensile strain core in the center of the workpiece. These results could be a valuable reference for designing the similar forging operations.     

Simulation of large forging flat-anvil stretching process and its optimization

In this paper, a kind of mathematic method for optimizing stretching process of large forgings is proposed. Distributions of effective strain within forged ingots is described by a Gauss function, which is obtained from the simulation of flat-anvil stretching process. Successive stretching is expressed by the superimposing Gauss functions. Optimized stretching process, with both homogeneous and certain strain in the center of forgings, is presented by derivation of this function. The relationship between effective strain and the values of feed is obtained during the successive stretching with a rotation angle of 90° and a feed displacement of 1/2 anvil width. The optimization result is verified by finite element simulation. Optimized value of feed obtained using this method can ensure both uniformity and forging penetration. It provides mathematic model and theoretic basis of optimizing large forging stretching process.     

Computer Aided Simulation on Precision Cold Forging of Universal Joint Cross

IntroductionThefiwtee1emenmethod(FEM)playsanextrmelyimPortantroleintheanalysesofengineeringproblems.ForalongtimethismethodhasmainlybeenaPPliedinthelinearfieldandshownitsgreatpower.HoweveealOtofnonlinearengineeringPrOblemsWhichcanneitherbesimPlyreducedtolinearonesnorrCPresentedbylinearlyanalogywhichshallchnsethePfacticalconditionsrelativelymuch,havechallengedfiniteelementmethod(FEM).RecentymuchProgresshasbeenmadebothinthemathematicalandmechanicaltheoryandthecomPulertechnologysothatevent…     

Microstructure Evolution of Different Forging Processes for 12％Cr Steel During Hot Deformation

Five forging experiments were designed and conducted to investigate the effect of process parameters on microstructure evolution during hot deformation for X12CrMoWVNbN10-1-1 steel.The experimental results indicated that average grain size became finer with the increasing number of upsetting and stretching.Especially,the size of stretching three times with upsetting twice had the most remarkable effect on refinement,and the size was only 27.36%of the original one.Moreover,the stress model was integrated into the software and finite element models were established.Simulation results demonstrated that the strain at center point of workpiece was far larger than critical strain value in each process,so that dynamic recrystallization(DRX) occurred in each workpiece,which implied DRX could occur for several times with the increasing number of upsetting and stretching,and uniform finer microstructure would be obtained.However,the results also showed that higher temperature was an unfavorable factor for grain refinement,so the times of heating should be limited for workpiece,and as many forging processes as possible should be finished in once heating.     

Simulation and analysis of microstructure evolution of IN718 in rotary forgings by FEM

A numerical analysis was performed to study the in?uence of process parameters on the microstruc-ture evolution of IN718 alloy in rotary forging using the finite element method(FEM).For this purpose, a constitutive equation considering the effects of strain hardening and dynamic softening of IN718 alloy was built.The constitutive equation and microstructure models were implemented into the finite element code to investigate the microstructure evolution during rotary forging subject to large deformations.The simulations were carried out in the ratio of initial height to diameter range 0.2-0.8, the angle of the rocker 3°-7° and the relative feed per revolution range 0.01-0.1 r-1.The research results revealed the deformation mechanism and the correlation of process parameters with the grain size evolution of IN718 alloy during rotary forging.These provide evidence for the selection of rotary forging parameters.     

半刚性基层材料抗裂性评价指标的灰色关联分析

利用灰色理论对试验得到的多种干缩、温缩指标与最大干缩应变和最大温缩应变的相关分析表明：与丰刚性基层材料的抗裂性关联度最高的干缩指标是干缩能抗裂系数．与半刚性基层材料的抗裂性关联度最高的温缩指标是温缩能抗裂系数。     

Numerical Simulation of Coupled Thermo-mechanical Behavior of a Cylinder Billet during Hot-forging Process

IntroductionInhotforging,variationanddistributiol1oftemperatureplayveryimportantroIeinviewofthermalstressesorthermalstrainaswe1lasthemateria1properties.MechanicaldefOrmationcangenerateheatbyfrictionalslidingand/ordissipatiOI1ofplasticwork.Theboundaryconditionfortemperatureismodifiedbythechangeinmaterialshape.Dietemperatureusuallyislowerthanworkpiecetemperatureandthisfactresultsindiechilling.Itsignificantlyaffectsthetemperatureoftheworkpiecea11d,consequently,alterstheflowstress.Whenthedieisr…     

Research on voids deformation welding condition for manufacturing of heavy forgings

Crushing and diffusion welding are two critical healing stages of interior void defects in heavy forgings. The healing result depends on many factors during the forging process, such as stress, temperature, deformation and type of material, while the void diffusion welding condition is still not well known at the present. This paper is concerned with the deformation welding condition of the closed void interface in heavy ingot during the hot forging process. A void crushing experiment is carried out to recognize the microstructure of the closed void interface. According to the healing mechanism at high temperature, a new physical simulation model is setup to study the deformation welding process of the closed void interface based on the theory of atom diffusion and the interface contact mechanics prototype. Compared with the experimental results, the influence of deformation degree, forming temperature and holding time on the welding quality is discussed, and then the deformation welding condition of closed void interface is presented. The proposed condition helps to improve forging technology and product quality.     

Two step forging process of spur gear based on rigid parallel motion

To improve the forging process of spur gear,the metal flow rule is investigated in detail,and a hypothesis of radial rigid-parallel-motive (RPM) flow mode is given. Based on the RPM mode a novel specific gear forging technology is put forward by introduced upend forging process and constrained divided-flow technique. Firstly,finite element method is used to simulate the upend forging pre-forming and RPM finish forging,and equivalent stress field and load-stroke curve are investigated. Secondly,a correspondi...     

轮轨摩擦耦合热弹性有限元分析模型

基于伽辽金变分原理,利用有限元方法,建立了轮轨摩擦耦合热弹性有限元分析模型,分析了轮轨摩擦热与钢轨接触区热膨胀位移、摩擦温度、应变和应力的关系。模型中温度场和位移场由耦合方程同时求解,但没有考虑惯性项和材料阻尼的影响。分析结果表明:耦合求解的温度场和位移场与非耦合求解的温度场和位移场的计算结果一致,钢轨表面各点滑动位移的方向与车轮滑动方向一致,垂向位移方向先负后正;钢轨表面各节点进入接触区后,温度快速上升,但高温持续时间短;在滑动方向上,钢轨接触点先受压应变后受拉应变作用,垂向受拉应变作用,滑动方向压应力明显高于垂向压应力,钢轨接触斑前后节点滑动方向应变符号相反;垂向高正应变区主要集中分布在接触斑后半轴上,最大剪应变与剪应力区在接触表层以下。     

增力式多向镦锻装置的研制

在通用压机上生产类似全纤维曲轴一类锻件的先进工艺为多向镦锻法。本文设计的新型增力式多向钮锻装置，在锻造接近结束时，可以增大水平锹粗力，其增力效果超过传统的ＲＲ锻造法及ＴＲ锻造法。     

突缘叉模锻件折叠缺陷分析

通过对缺陷的内部结构进行分析,发现突缘叉锻件法兰底面产生缺陷的主要原因是模锻前制坯工艺不合理,造成模锻时金属回流,产生折叠.提出改进制坯工艺消除锻件的缺陷的方案,经工艺和生产验证,消除了锻件缺陷,提高了锻件质量,取得满意效果,该工艺的成功应用,可为同类型产品的生产提供借鉴.     

5CrNiMo钢锻模液态模锻工艺试验

采用液态模银代替自由锻造生产转向螺母5CrNiMo锻模，给出了其下模结构设计参数，介绍了5CrNiMo合金液态模锻工艺参数取位范围，分析了制件的质量。     

Computer Simulation of Thermal-Mechanical Processing

AlterationIntroductionThereisastrongini6ractionamongtemPetalrefield,strCssfield,andmicrosttuctutulaltOrationinm8terialsduringtheirhotworking[l'2].Especiallyduringthecoolingprocess,inwhichtemPeratorechangnsgreatly,intendionsbecomemorecomplexbecauseoftransformationoccurmnce.Duringthehotdeformation,thingswillaPpearsuchas:a.hotdeformation,relatedtostressfieId,changesessentiallytheshaPeofmaterialsandcausesthevariationofthecontactstatebetWeenthedieandsample,resultinginchangeofthethermalboundnyco…     

模具间隙对液态模锻溢料的影响

通过液态模锻成型压力和温度参数对模具间隙影响的研究,以及模具结构分析,找出了由于模具间隙变化造成溢料的原因,提出了解决方案,对液态模锻模具设计具有一定的参考价值。     

电液锤改造的难点与解决办法

换头节能改造是对模锻锤和空气锤进行改造的有效方法，可以取得显著的经济效益和社会效益。主要介绍了电液锤换头改造模锻锤和空气锤过程中遇到的突出问题及解决的办法。     

Optimization of pellet induration process parameters in rotary kiln using simulation results

In order to optimize the pellet induration process parameters of rotary kiln, a mathematical model is developed and solved by using commercial software FLUENT. Orthogonal regression has been performed by using the simulated results of the pellet induration in rotary kiln. The functional relations between pellet induration quality and process parameters are obtained. The main parameters that affect the thermal process are also discussed. The results show that the high temperature zone is longer and the local high-temperature could be avoided while the velocity difference decreases between the secondary air and the carbon particle, which leads to more uniformed temperature distribution and better induration quality. The work gives a right direction on improving of pellet production.     

辊锻模型槽与锻件轮廓曲面的几何分析

通过对辊锻模与锻件的啮合运行分析,发现了锻件轮廓也型槽轮廓存在着共轭关系,导出了共轭曲面参数方程,此结果对于精确,高效设计辊锻模具具有重要意义 。