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Minimum additional material volume prediction for preform product by using abductive network and Taguchi method

Lin F. C., Lin S. Y., Hsu Y. C., Lee B. C., Kwan C. T.

Archives of Materials Science and Engineering

2008

Vol. 33, nr 1

57-60

Purpose: To predict the minimum value of additional material volume for an acceptable preform product. To predict an acceptable preform product without shape defect such as unfilling in a closed-die forging operation. Design/methodology/approach: In order to reduce the number of experiments, an orthogonal array from the Taguchi's experimental method will be utilized to design the process parameter combinations for database sets to promote the prediction precision. Also, in order to reduce the number of experiments to get the minimum additional material volume of preform, the abductive network is applied to synthesize the data sets obtained from the numerical simulation. Findings: The minimum additional material volume can be determined as 7.6% for an acceptable preform product in conjunction with the billet settle position, E, of 11.8 mm and the aspect ratio of width to height, B/H, of 1.4. Research limitations/implications: The Taguchi method can be used to narrow the ranges of process parameters for database sets which can promote the precision of abductive network to search for the the minimum additional material volume for an acceptable preform product. The abductive network is applied to synthesize the data sets obtained from the numerical simulation of the reduced ranges of the process parameters. Practical implications: The combination of the abductive network and Taguchi method can be used as a reference and guidance for the development of searching the minimum or maximum value of one of the process parameters, accompanying by the other suitable parameters. Originality/value: An assessment model of the closed-die forging process is developed using a neural network system and Taguchi method. Based on the developed neural network, the additional material volume of preform product, one of the forging process parameters can be minimum accompanying by the other suitable process parameters to get an acceptable product.

Design of manufacturing of welding neck type rings

Malinowski Z., Madej W., Musiał A., Hajduk Z., Wolski A.

Metallurgy and Foundry Engineering

2005

Vol. 31, No 2

201-210

Computer aided design of the rolling process for welding neck 20" and 24" type rings on the Thyssen—Wagner 125—100 mill is described in the paper. Numerical simulations of processes of preform shaping and ring rolling were performed using ring-roll finite element software. The optimal shape of the preform and rolling curve were selected on the basis of results of simulations, as well as on the basis of experimental data. Values of stresses, strains, strain rates and temperatures during rolling were determined and resutts were validated by comparison with the data monitored during the real industrial process. Obtained results were used for the design of tools for forging and rolling of welding neck type rings.

W pracy przedstawiono projektowanie procesu walcowania pierścieni kołnierzowych typu welding neck 20" and 24" w walcarce typu Thyssen-Wagner RAW 125-100. Komputerowa symulacja procesu kształtowania przedkuwki i walcowania pierścieni została przeprowadzona z wykorzystaniem programu Ring-Roll opartego na metodzie elementów skończonych. Na podstawie wyników symulacji oraz wyników doświadczalnych procesu walcowania pierścieni, dobrano optymalny kształt przedkuwki i krzywą walcowania dla danego typu pierścienia. Wartości naprężeń, odkształceń, prędkości odkształcenia oraz temperatury zostały określone dla poszczególnych etapów walcowania, a uzyskane wyniki poddano weryfikacji z danymi uzyskanymi z rzeczywistego procesu walcowania przeprowadzonego w warunkach przemysłowych. W oparciu o przedstawione wyniki, zaprojektowano narzędzia do kucia oraz walcowania pierścieni kołnierzowych.