Abstract
Hot forging is a metalworking process in which metals are plastically deformed above their recrystallization temperature, allowing the material to retain its deformed shape as it cools. In today's industry, the performance of the tools used during the hot forging process has always been a subject of interest. Although it is known that, the tool life used affects 10% of the design costs of the total budget, 80% of the total production costs are determined during the design stages. For this reason, minimizing mechanical stress and changing the die design, so as to optimize the tool life and reduce the cost, have been attractive. In this study, finite volume analysis was performed on 31CrV3 steel using the multi-stage forming process of hot closed die forging using Simufact Forming v16 software. 56NiCrMoV7 hot work tool steel was used as die material and X153CrMoV12 as template blade raw material. In this article, 3 state variables, effective plastic strain, equivalent stress and temperature were evaluated for two different die designs of multi-stage forming processes such as pre-forming, final forging, and cutting. The results were compared for cost for single and dual dies. For both die designs, the initial temperature of the billet is 1100-1200 ºC and the die temperature is 100-110 ºC. Finally, comparative analyzes of both die designs for three state variable parameters were performed in terms of mechanical properties and cost. The main focus is on calculating mechanical properties and cost based on available process parameters using subroutines during the incorporation of different die designs. According to the results obtained from the simulation study, the manufacturability of the product has been proven, the effect of the changes in the die and workpiece design on the cost have been investigated, and the final performance has been revealed by evaluating the profit rate.
Supporting Institution
IZELTAS IZMİR EL ALETLERI SANAYİ VE TİCARET A.S.
Thanks
The authors would like to thank IZELTAŞ El Aletleri Sanayi ve Ticaret A.Ş. and R&D Center Manager Dogan OZTAN for their support of the study.
References
- Altan T., Shirgaokar M. Simulation based process design for improvement of profitability in the hot forging industry. In 19th International Forging Congress 2008; #615.
- Campi F., Mandolini M., Favi C., Checcacci E., Germani M. An analytical cost estimation model for the design of axisymmetric components with open-die forging technology. The International Journal of Advanced Manufacturing Technology 2020; 110(7): 1869-1892.
- Chander S., Chawla V. Failure of hot forging dies–an updated perspective. Materials Today Proceedings 2017; 4(2): 1147-1157.
- Jha SK. Cost optimization of a forged steel crankshaft in global manufacturing environment. International Journal of Mechanical Engineering Research and Technology 2016; 2 (2): 16-28.
- Kilerci İ. Computer aided investigation of the effect of mechanical properties on metal forming production parameters. Manisa Celal Bayar Üniversitesi, Manisa, Doctoral Dissertation 2017.
- Kumar OP., Kumar V. Optimization of the process parameters of forging of pitman arm. International Journal of Engineering Science Invention 2019; 8(08): 01-11.
- Maarefdoust M., Kadkhodayan M. Simulation and analysis of hot forging process for industrial locking gear elevators. 14th International Conference on Applied Mechanics and Mechanical Engineering 2010; 14, 1-10.
- Meng F., Labergere C., Lafon P. Methodology of the shape optimization of forging dies. International Journal of Material Forming 2010; 3(1): 927-930.
- Milutinović M., Baloš S., Plančak M., Movrin D. Comparison of some mechanical properties and micro-topography of a component with non-axisymmetric geometry manufactured by cold orbital and hot forging. Journal of Materials Processing Technology 2017; 249: 179-192.
- Rezaie K., Ostadi B., Torabi SA. Activity-based costing in flexible manufacturing systems with a case study in a forging industry. International Journal of Production Research 2008; 46(4): 1047-1069.
- Santos AD., Duarte JF., Reis A., Rocha B., Neto R., Paiva R. The use of finite element simulation for optimization of metal forming and tool design. Journal of Materials Processing Technology 2001; 119(1-3): 152-157.
- Shirgaokar M. Technology to improve competitiveness in warm and hot forging: Increasing die life and material utilization. The Ohio State University, Ohio Doctoral Dissertation 2008.
- Takemasu T., Vazquez V., Painter B., Altan T. Investigation of metal flow and perform optimization in flashless forging of a connecting rod. Journal of Material Process Technology 1996; 59, 95-105.
Abstract
Sıcak dövme, metallerin yeniden kristalleşme sıcaklıklarının üzerinde plastik olarak deforme edildiği ve malzemenin soğudukça deforme şeklini korumasını sağlayan bir metal işleme sürecidir. Günümüz endüstrisinde sıcak dövme işlemi sırasında kullanılan takımların performansı her zaman ilgi konusu olmuştur. Kullanılan takım ömrünün toplam bütçenin tasarım maliyetlerinin %10'unu etkilediği bilinmesine rağmen, toplam üretim maliyetlerinin %80'inin tasarım aşamalarında belirlendiği bilinmektedir. Bu nedenle, takım ömrünü optimize etmek ve maliyeti azaltmak için mekanik stresi en aza indirmek ve kalıp tasarımını değiştirmek cazip olmuştur. Bu çalışmada, Simufact Forming v16 yazılımı yardımıyla, kapalı kalıpta sıcak dövmenin çok aşamalı şekillendirme prosesi kullanılarak, 31CrV3 çeliği üzerinde sonlu hacim analizi yapılmıştır. Kalıp malzemesi olarak 56NiCrMoV7 sıcak iş takım çeliği, şablon bıçak hammaddesi olarak X153CrMoV12 kullanılmıştır. Bu makalede, ön şekillendirme, son dövme ve kesme gibi çok aşamalı şekillendirme proseslerinin iki farklı kalıp tasarımı için 3 durum değişkeni, efektif plastik gerinimi, eşdeğer gerilmesi ve sıcaklık değerlendirilmiştir. Sonuçlar, tekli ve ikili kalıplar için maliyet açısından karşılaştırılmıştır. Her iki kalıp tasarımı için de iş parçasının başlangıç sıcaklığı 1100-1200 ºC ve kalıp sıcaklığı 100-110 ºC'dir. Sonuç olarak, üç durumlu değişken parametre için her iki kalıp tasarımının mekanik özellikler ve maliyet açısından karşılaştırmalı analizleri yapılmıştır. Ana odak noktası, farklı kalıp tasarımlarının dahil edilmesi sırasında alt rutinler kullanılarak mevcut proses parametrelerine dayalı mekanik özelliklerin ve maliyetin hesaplanmasıdır. Simülasyon çalışmasından elde edilen sonuçlara göre ürünün üretilebilirliği ispatlanmış, kalıp ve iş parçası tasarımındaki değişikliklerin maliyete etkisi araştırılmış ve elde edilen kar oranı değerlendirilerek nihai performans ortaya konmuştur.
References
- Altan T., Shirgaokar M. Simulation based process design for improvement of profitability in the hot forging industry. In 19th International Forging Congress 2008; #615.
- Campi F., Mandolini M., Favi C., Checcacci E., Germani M. An analytical cost estimation model for the design of axisymmetric components with open-die forging technology. The International Journal of Advanced Manufacturing Technology 2020; 110(7): 1869-1892.
- Chander S., Chawla V. Failure of hot forging dies–an updated perspective. Materials Today Proceedings 2017; 4(2): 1147-1157.
- Jha SK. Cost optimization of a forged steel crankshaft in global manufacturing environment. International Journal of Mechanical Engineering Research and Technology 2016; 2 (2): 16-28.
- Kilerci İ. Computer aided investigation of the effect of mechanical properties on metal forming production parameters. Manisa Celal Bayar Üniversitesi, Manisa, Doctoral Dissertation 2017.
- Kumar OP., Kumar V. Optimization of the process parameters of forging of pitman arm. International Journal of Engineering Science Invention 2019; 8(08): 01-11.
- Maarefdoust M., Kadkhodayan M. Simulation and analysis of hot forging process for industrial locking gear elevators. 14th International Conference on Applied Mechanics and Mechanical Engineering 2010; 14, 1-10.
- Meng F., Labergere C., Lafon P. Methodology of the shape optimization of forging dies. International Journal of Material Forming 2010; 3(1): 927-930.
- Milutinović M., Baloš S., Plančak M., Movrin D. Comparison of some mechanical properties and micro-topography of a component with non-axisymmetric geometry manufactured by cold orbital and hot forging. Journal of Materials Processing Technology 2017; 249: 179-192.
- Rezaie K., Ostadi B., Torabi SA. Activity-based costing in flexible manufacturing systems with a case study in a forging industry. International Journal of Production Research 2008; 46(4): 1047-1069.
- Santos AD., Duarte JF., Reis A., Rocha B., Neto R., Paiva R. The use of finite element simulation for optimization of metal forming and tool design. Journal of Materials Processing Technology 2001; 119(1-3): 152-157.
- Shirgaokar M. Technology to improve competitiveness in warm and hot forging: Increasing die life and material utilization. The Ohio State University, Ohio Doctoral Dissertation 2008.
- Takemasu T., Vazquez V., Painter B., Altan T. Investigation of metal flow and perform optimization in flashless forging of a connecting rod. Journal of Material Process Technology 1996; 59, 95-105.
Details
| Primary Language | English |
|---|---|
| Subjects | Mechanical Engineering |
| Journal Section | RESEARCH ARTICLES |
| Authors | |
| Publication Date | February 23, 2022 |
| Submission Date | December 6, 2021 |
| Acceptance Date | January 15, 2022 |
| Published in Issue | Year 2022 Volume: 5 Issue: Özel Sayı |
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