Investigating the effects of cross wedge rolling preforming operation and die forging with flash brakes on forging titanium hip implants

authored by: Bernd Arno Behrens, Malte Stonis, Thoms Blohm, Johannes Richter
Abstract: To reduce production costs of forged parts, different approaches are possible. Especially for valuable materials like titanium, material costs represent a large part of the production costs. Therefore, reducing the initial material can decrease the total costs significantly. In order to identify the potential for improvements, an existing forging sequence was investigated. For a titanium hip implant, a forging sequence was developed. To reduce the initially needed material, cross wedge rolling as a preforming operation and die forging with flash brakes was investigated. The influence of the different stages on the final result was analysed and presented in detail. To increase the prediction accuracy of the newly developed flash-reduced forging sequence and decrease iteration loops of die designs, feasible simulation parameters considering the boundary conditions of the forging environment were investigated. This is done using Finite Element Analysis (FEA), considering form filling, process stability, die stress and press forces. Using cross wedge rolling and die forging with flash brakes, the newly developed forging sequence reduces the flash rate significantly from 69% to 32%.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
External Organisation(s): Institut für integrierte Produktion Hannover (IPH)
Type: Article
Journal: International Journal of Material Forming
Volume: 11
Pages: 67-76
No. of pages: 10
ISSN: 1960-6206
Publication date: 01.2018
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: General Materials Science
Electronic version(s): https://doi.org/10.1007/s12289-016-1329-0 (Access: Closed)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{c08e75d9ab6c493a86481f79222c22dd,
title = "Investigating the effects of cross wedge rolling preforming operation and die forging with flash brakes on forging titanium hip implants",
abstract = "To reduce production costs of forged parts, different approaches are possible. Especially for valuable materials like titanium, material costs represent a large part of the production costs. Therefore, reducing the initial material can decrease the total costs significantly. In order to identify the potential for improvements, an existing forging sequence was investigated. For a titanium hip implant, a forging sequence was developed. To reduce the initially needed material, cross wedge rolling as a preforming operation and die forging with flash brakes was investigated. The influence of the different stages on the final result was analysed and presented in detail. To increase the prediction accuracy of the newly developed flash-reduced forging sequence and decrease iteration loops of die designs, feasible simulation parameters considering the boundary conditions of the forging environment were investigated. This is done using Finite Element Analysis (FEA), considering form filling, process stability, die stress and press forces. Using cross wedge rolling and die forging with flash brakes, the newly developed forging sequence reduces the flash rate significantly from 69% to 32%.",
keywords = "Cross wedge rolling, Finite element simulations, Flash brakes, Flash-reduced, Forging, Forging sequence development",
author = "Behrens, {Bernd Arno} and Malte Stonis and Thoms Blohm and Johannes Richter",
note = "Publisher Copyright: {\textcopyright} Springer-Verlag France 2016. Copyright: Copyright 2021 Elsevier B.V., All rights reserved.",
year = "2018",
month = jan,
doi = "10.1007/s12289-016-1329-0",
language = "English",
volume = "11",
pages = "67--76",
journal = "International Journal of Material Forming",
issn = "1960-6206",
publisher = "Springer Paris",
number = "1",
}