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Important Aspects Forging Prediction Rodrigo Lobenwein – Commercial Alisson Duarte – Engineering May 21 st , 2018 SIXPRO Virtual&Practical Process [email protected] / www.sixpro.pro
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Important Aspects
Forging Prediction
Rodrigo Lobenwein – Commercial
Alisson Duarte – Engineering
May 21st, 2018
SIXPRO Virtual&Practical Process
[email protected] / www.sixpro.pro
• Material Properties
• Heat Treatment
• Forging
• Extrusion
• Rolling
• Wire drawing
• Sheet Metal Forming
2
Agent in Brazil
Agent in South America
SG PROJETOS
Center for Precision FormingOSU/The Ohio State University
Partners:
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Furnace
Rammer
Ram
Forging
Furnace
Billet
Exit ramp
Rammer
Preform
Ram
Upper Die
Lower Die
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Flange
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Dies:• Material;• Temperature;• Wear;• Plastic deformation;• Elastic deformation;• Fracture.
Interface Die/Material:• Friction;• Heat exchange;• Lubrication;• Part residue.
Material;• Mechanical properties;• Temperature distribution;• Oxidation;• Final form and dimensions;• Fracture;• Phase transformation.
Presses;• Equipment;• Velocity;• Force.
Important Aspects
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FEM Mesh
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Node
Element
Billet being upset
Mesh Density
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Engineering Curve
True stress/strain curve
Yield Stress= 300 MPa
oA
FT =
o
o
L
LLe
−=
constant
constant
Engineering
A
F=
=
0
lnL
L
True
Strain
Str
ess (
MP
a)
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Material
Elastic portion
Flow Curve
Strain
Str
ess (
MP
a)
Flow Curve
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Billet
Upper
Die
Bottom
Die
FEM Model
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Interface problems Proper relationship
between part and die
Mesh Influence
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Punch stroke (mm)
Forg
ing
Loa
d (
ton)
Effect on the Results
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Symmetry plane
Symmetry plane
Points for profile measurement
Precision Gears
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Normalized Cockroft and Latham 𝜖𝑒𝑓𝑖:𝜖𝑒𝑓𝑖 𝜎1
𝜎𝑒𝑓𝑑𝜀𝑒𝑓
Oyane:𝜖𝑒𝑓𝑖𝜖𝑒𝑓𝑖(1 +
𝜎𝑚
𝜎𝑒𝑓)𝑑𝜀𝑒𝑓
Ayada:𝜖𝑒𝑓𝑖𝜖𝑒𝑓𝑖 𝜎𝑚
𝜎𝑒𝑓𝑑𝜀𝑒𝑓
Normalized C&L
Fracture (Damage)
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Inicial
50.000 Golpes
100.000 Golpes
150.000 Golpes
Number of
forged parts
Die Wear
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Hammer Forging
Symmetry line
Process
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Symmetry line
Simulation
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Effective Strain
Effe
ctiv
e St
ress
(M
Pa)
Effect of Temperature
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True Effective Strain
Engineering Effective Strain
Effective Strain
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Chemical Composition
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Taking into account the Processing History
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Tensile Test
Forging
Effective Strain
Effe
ctiv
e St
ress
(M
Pa)
Effect of Strain Rate
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Strain Rate (s-1)
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Burr formation lineCentral region of thickness “t”
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Heavy Forged Part
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Preforming
(a)
Central region of thickness “2t” impossible to cut
Burr formation line
Possible defect (underfill)
Underfill
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Problem
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Results
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Simulation – New Preform
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Forged Geometry
Anterior Novo
Matéria Prima 30,5% 24,0% volume
Cortar 1,4% 1,4% não considerado
Forjar/Rebarbar 18,9% 5,1% quatidade de golpes
Usinagem central 12,9% 0,0% tempo de usinagem
Têmpera e Revenimento 6,6% 6,6% não considerado
Jatear 0,4% 0,4% não considerado
Usinagem acabamento 29,4% 29,4% não considerado
Total 100,0% 66,7%
Redução
considerada
Custos relativos (%)OperaçãoOperation
Relative costs (%)
Before New
Considered Reduction
Raw material
Piercing
Forging/Deburring
Central Machining
Quenching and Tempering
Shoot peening
Finishing machining
Volume
Not considered
Blow Number
Machining Time
Not considered
Not considered
Not considered
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Costs
Tentativa Solução AbordagemPeso do
tarugo (kg)
Espessura
central (mm)
Margem de
lucro (%)Resultado Justificativa
1Pré-forma
cúbica
Tentativa
e erro30,0 12 - Impossível
Falta de
preenchimento
2Aumento no
volume
Tentativa
e erro38,5 25 - 1 Inviável
Aumento no volume
e na usinagem
3Modificação
da pré-formaSimulação 30,0 0 + 13 Viável
Redução no volume
e na usinagem
Attempt Solution ApproachBillet
Weight (Kg)Central
thickness (mm)
Profit Margin
Result Justification
Cubic Preform
Volume increase
Preform modification
Trial and error
Trial and error
Simulation
Impossible
Not viable
Viable
Underfill
Increase in the volume and machining
Reduction in the volume and machining
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Viability
Numerical Method
Material Science
Fabrication Process
Process Simulation
Cost Analysis
Implementing Simulations
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Thank you!
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