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Analysis and Improvement of an Industrial Process of Hot Die Forging of an Elongated Forging Tipped with a Joggle with the Use of Numerical Simulation Results

Hawryluk Marek, Rychlik Marcin, Polak Sławomir, Zwierzchowski Maciej, Dudkiewicz Łukasz, Marzec Jan, Jabłoński Paweł

Advances in Science and Technology. Research Journal

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2023

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Vol. 17, no 2

192--205

EN

The article performs an analysis of a hot die forging process of producing an elongated forging ended with a joggle in a double system realized on a crank press Masey 1300 t, in open dies, in 3 operations. The thermomechanical model of the forging process considering the changes in the grain size and the forging material recrystallization was elaborated with the use of the calculation packet Qform 7. In the first place, an in-depth analysis of the currently realized forging technology was made, with a special consideration of the temperature changes in the tools as well as in the formed forging. Next, numerical modelling of the process was carried out, as a result of which the following were obtained: correct filling of the tool impressions by the deformed material, the temperature distributions for the forging and the tools, the plastic deformation distributions (considering the thermally activated phenomena), the changes in the grain size and the forging force courses. The results obtained from FEM enable a thorough analysis of the forging process, including: the effect of the deformation time and temperature on the grain size in the forging material, which was confirmed by the microstructure examination results.

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An implementation of robotization for the chosen hot die forging process

Hawryluk Marek, Rychlik Marcin

Archives of Civil and Mechanical Engineering

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2022

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Vol. 22, no. 3

art. no. e119

EN

The article discusses the possibilities of introducing selected aspects and problems in the robotization of the workstation in the hot die forging process, the production of the yoke forging carried out on a crank press in a manual system. The implementation of the developed solution was performed to increase the production efficiency without lowering the quality and mechanical parameters of the produced forgings and with preserved durability of the forging instrumentation. The conducted investigations included numerous aspects of the whole process line, with a special consideration of the adjustment of the currently realized technology to the working conditions of the robots in reference to the ejector system ensuring proper collection and relocation of the forgings by the manipulator grippers in the consecutive operations. The conduct also included the selection and localization of the robots and the grippers solutions, as well as the changes in the tool construction aiming at adjusting it to the gripper pins as well as collecting the hot charge material from the heater. Implementing robotization into one of the most difficult production processes aimed at replacing the role of a human by transferring the competences from the operator of the die forging process onto a supervising person, where all the activities are realized automatically, thus eliminating the effect of the human factor on the quality of the manufactured product. Additionally, the robotization of the forging process brought a lot of tangible benefits, such as stability and repeatability of the process (reduction of reject rate), as well as increased efficiency and quality of the forgings.

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Analiza technologii kucia swobodnego z wykorzystaniem makroskopowych efektów mikropasm ścinania

Piątkowski P., Kukuryk B.

Rudy i Metale Nieżelazne

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2005

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R. 50, nr 10-11

576-581

PL

Przedstawiono analizę technologii kucia swobodnego z wykorzystaniem makroskopowych efektów mikropasm ścinania w aspekcie technologicznej efektywności i wysokiej jakości odkuwek. Do symulacji schematu płynięcia metalu w procesie kucia zastosowano metodę elementów skończonych z zastosowaniem lepko-plastycznego modelu odkształcanego ciała. Analizę numeryczną wykonano z wykorzystaniem programu QForm, w warunkach przestrzennego stanu odkształcenia. Przedstawiono nowe konstrukcje narzędzi kuźniczych oraz opracowano odpowiednią metodykę kucia, która prowadzi do silnej koncentracji dodatkowych odkształceń postaciowych, tzw. mikropasm ścinania.

EN

In the paper the free forging technology analysis with use of macroscopic effects of micro-shear bands regarding technological efficiency and high quality of forgings has been presented. Finite Elements Method and visco-plastic model of the deformed element has been used to simulate metal flow in forging process. The numerical analysis was performed on QForm programme in the three-dimensional deformation state. In the paper new constructions of the forging tools was introduced together with the adequate forging methodology leading to strong concentration of the additional non-dilatation strains as thin transcrystalline layers — micro-shear bands.

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Modelowanie numeryczne jako narzędzie wspomagające zarządzanie jakością

Sińczak J., Łukaszek-Sołek A.

Hutnik, Wiadomości Hutnicze

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2003

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Vol. 70, nr 6

255--259

PL

Na przykładzie odkuwki matrycowej o złożonym kształcie wykonano kilka wariantów obliczeń numerycznych technologii kucia w przestrzennym stanie odkształcenia. Dokonano wyboru optymalnej technologii, gwarantującej żądaną jakość finalnego produktu, na podstawie rozkładu naprężeń średnich i intensywność odkształcenia oraz eliminację wad w postaci zakuć.

EN

In the paper some of variants of numerical modelling of forging technology in three-dimensional state of strain are done for the drop forging with complex shape. The choice of optimal technology is made on the basis of distribution of mean stresses and intensity of strains and elimination of defects in the form of laps that guarantee to have demanded quality of final product.