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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

100%

Hawryluk M. , Rychlik M. , Polak S. , Zwierzchowski M. , Dudkiewicz Ł. , Marzec J. , Jabłoński P.

tom Vol. 17, no 2

192--205

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.

Capabilities of numerical simulation support for defect investigations in die forgings

84%

Hawryluk M. , Polak S. , Dudkiewicz Ł. , Marzec J. , Jabłońska M. , Suliga M. , Tkocz R. , Korpala G.

Computer Methods in Materials Science

2024

tom Vol. 24, No. 1

25--36

The article concerns the use of the results of numerical simulations, primarily for the detection of defects in forged products identified at various stages, along with the analysis of the geometry of forgings and the way in which the material flows in tools. The work presents the results of measurements and analyses using numerical modelling based on computational packages dedicated to forging processes such as: QForm, Forge, etc., which are equipped with special functions that significantly facilitate analyses by both technicians and designers. These functions include: contact of the deformed material with the tool, flow line distribution, “trap” or “fold” functions for detecting forging defects, as well as other technological parameters and physical sizes, which are crucial in the case of a comprehensive analysis of the industrial die forging process. The novelty of the work is the presentation of the possibility of simultaneously combining many different non-destructive techniques and methods, e.g. results of FE simulations with 3D reverse scanning, minimizing interference in the industrial process. The research carried out allows for the thorough and rapid analysis of the correctness of the deformation of the forging material for selected forging processes, along with the presentation of methods for their prevention and solving various technological and engineering problems, which is particularly important in terms of reliability and production efficiency.