Numerical and experimental investigations on fold formation in forged parts

verfasst von: B. A. Behrens, T. Matthias, M. Kazhai
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 for quality are increasing. Therefore it is inalienable to detect failures in parts in earlier production process stages, to avoid additional costs and loss of time. In bulk metal forming processes forging folds, which predominantly occur at the equatorial section in upsetting processes of hollow parts, are less investigated in comparison with folds in sheet metal forming process. Some previous studies already showed the main influences on the formation of forging folds and process limits using processes, in which forging folds occur predominantly [1, 2, 3]. More studies were carried out on investigations with focus on numerical identifications of folds [1,4]. In one of 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. In this work, the numerical approach is transferred to the three-dimensional case, to investigate the accuracy and validation of the previous results to establish a base for further investigations. The determined influences on the formation of forging folds are investigated for three-dimensional fold formation and compared with the experimental results. Further investigations on the factors, which lead to forging folds, were carried out numerically and experimentally. Here the numerical results were validated by means of metallographic microsection of the forged parts, whereby the material flow and the geometric characteristics of folds were considered. The results of this work serves as a basis for an automatic optimization of the process-parameters to prevent formation of forging folds. This will be realized by an optimization tool, which is nowadays integrated in commercial FE software systems. Thus, it should be possible to individually optimize the process, so that failures in parts can be avoided. Furthermore the results of this work serve also as basis for further investigations on a better friction modeling comparing classic friction models with the IFUM-friction model..
Organisationseinheit(en): Institut für Umformtechnik und Umformmaschinen
Typ: Aufsatz in Konferenzband
Seiten: 212-220
Anzahl der Seiten: 9
Publikationsdatum: 23.05.2014
Publikationsstatus: Veröffentlicht
Peer-reviewed: Ja
ASJC Scopus Sachgebiete: Allgemeine Materialwissenschaften, Werkstoffmechanik, Maschinenbau
Elektronische Version(en): https://doi.org/10.4028/www.scientific.net/kem.611-612.212 (Zugang: Geschlossen)
: Details im Forschungsportal „Research@Leibniz University“

BibTeX

@inproceedings{9fee3558d5a242d3ae62dcd98f6406d1,
title = "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 for quality are increasing. Therefore it is inalienable to detect failures in parts in earlier production process stages, to avoid additional costs and loss of time. In bulk metal forming processes forging folds, which predominantly occur at the equatorial section in upsetting processes of hollow parts, are less investigated in comparison with folds in sheet metal forming process. Some previous studies already showed the main influences on the formation of forging folds and process limits using processes, in which forging folds occur predominantly [1, 2, 3]. More studies were carried out on investigations with focus on numerical identifications of folds [1,4]. In one of 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. In this work, the numerical approach is transferred to the three-dimensional case, to investigate the accuracy and validation of the previous results to establish a base for further investigations. The determined influences on the formation of forging folds are investigated for three-dimensional fold formation and compared with the experimental results. Further investigations on the factors, which lead to forging folds, were carried out numerically and experimentally. Here the numerical results were validated by means of metallographic microsection of the forged parts, whereby the material flow and the geometric characteristics of folds were considered. The results of this work serves as a basis for an automatic optimization of the process-parameters to prevent formation of forging folds. This will be realized by an optimization tool, which is nowadays integrated in commercial FE software systems. Thus, it should be possible to individually optimize the process, so that failures in parts can be avoided. Furthermore the results of this work serve also as basis for further investigations on a better friction modeling comparing classic friction models with the IFUM-friction model..",
keywords = "Bulk metal forming, FEM, Forging folds",
author = "Behrens, {B. A.} and T. Matthias and M. Kazhai",
note = "Copyright: Copyright 2020 Elsevier B.V., All rights reserved.; 17th Conference of the European Scientific Association on Material Forming, ESAFORM 2014 ; Conference date: 07-05-2014 Through 09-05-2014",
year = "2014",
month = may,
day = "23",
doi = "10.4028/www.scientific.net/kem.611-612.212",
language = "English",
isbn = "9783038351061",
series = "Key Engineering Materials",
publisher = "Trans Tech Publications Ltd",
pages = "212--220",
booktitle = "Material Forming ESAFORM 2014",
}