Numerical and Experimental Investigations on Fold Formation in Forged Parts

Abstract:

On component-side the process limits of bulk metal forming processes are limited by defects in parts, like folds or cracks. Considering the time and cost aspect, the complexity of forged parts and the demands on quality are increasing. Therefore in production processes it is inalienable to detect failures in parts in earlier process stages, to avoid additional costs and loss of time. One of the comparatively less investigated failures in bulk metal forming processes are forging folds, which predominantly occur at the equatorial section in upsetting processes of hollow parts. Some previous studies showed the main influences on the formation of forging folds [1, 2, 3]. In these studies i.a. at the Institute of Forming Technology and Machines an algorithm was developed and implemented in a commercial FE-Software-System, which is able to detect forging folds in bulk metal forming processes. However, the algorithm is only valid for two-dimensional models.

• Periodical: Key Engineering Materials (Volumes 611-612)
• Pages: 212-220
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.611-612.212
• Online since: May 2014
• Authors: Bernd-Arno Behrens, Thorsten Matthias, Mohammad Kazhai*
• Keywords: Bulk Metal Forming, Finite Element Method (FEM), Forging Folds

References

[1] Prof. Dr. -Ing. B. -A. Behrens, Dipl. -Ing. S. Röhr, Dr. -Ing. A. Hundertmark, Dipl. -Ing. F. Schäfer: Untersuchung zur numerischen Ermittlung von Schmiedefalten, Hannover, UTF-Science, 2/(2007).

DOI: 10.1002/stab.199903290

[2] Prof. Dr. -Ing. M. Liewald, Dipl. -Ing. T. Schiemann: Leichtbau durch Kaltmassivumformung - Erweiterung der Verfahrensgrenzen beim Bundstauchen von hohlen Fließpressteilen, Schmiedejournal, Ausgabe 03/2013, 58093 Hagen.

[3] E. Rauschnabek, B. Adams: LightWeightPro- Leichtbauteile großer Länge aus Rohrhalbzeug umformen, Werkstatttechnik online (wt online), Springer-VDI-Verlag GmbH & Co. KG, 2013, Düsseldorf.

DOI: 10.37544/1436-4980-2013-10-796

[4] B. -A. Behrens, R. Nickel, M. Stonis: Simulation algorithm fort he assessment and modification of multi-directional forging processes and tool geometries, German Academic Society for Production Engineering (WGP), 6: 187-198, Springer, (2012).

DOI: 10.1007/s11740-012-0364-z

[5] Dieterle. K.: Faltenbildung als Verfahrensgrenze beim Stauchen von Hohlkörpern, Dissertation, Universität Stuttgart, (1975).

[6] Prof. Dr. -Ing. B. -A. Behrens, Dr. -Ing. A. Bouguecha, Dr. -Ing. A. Hundertmark: Aktuelle Forschungsergebnisse am Institut f. Umformtechnik und Umformmaschinen: Standmengenoptimierte Werkzeugauslegung in der Warmmassivumformung, (Hrsg. ) Tagungsband 19. Umformtechnisches Kolloquium Hannover, pp.52-60, (2008).

DOI: 10.1007/978-3-642-48208-3_2

[7] J. -h. Songa, Y. -T. Im: Process design for closed-die forging of bevel gear by finite element analysis, Journal of Materials Processing Technology, (2007).

DOI: 10.1016/j.jmatprotec.2007.04.081

[8] T. Altan, V. Vazquez: Numerical Process simulation for Tool and Process Design in Bulk Metal Forming, CIRP Annals. Manufacturing Technology, Elsevier Ltd., (1996).

DOI: 10.1016/s0007-8506(07)60514-9

[9] G. Gantar, T. Pepelnjak, K. Kuzman: Optimization of sheet metal forming processes by the use of numerical simulations, Journal of Materials Processing Technology, Volume 130-131, pp.54-59, Elsevier B.V., 12/(2002).

DOI: 10.1016/s0924-0136(02)00786-0

[10] B.P.P.A. Gouveia, J.M.C. Rodrigues, P.A.F. Martins: Fracture predicting in bulk metal forming, International Journal of Mechanical Sciences, volume 38, pp.361-372, Elvetier Ltd. 04/(1996).

DOI: 10.1016/0020-7403(95)00069-0