Research and Development in Forging at ERC/NSM evaluation of cold forging lubricants. Die Failure (Wear/ Fracture) Prediction 3. Process Modeling / Tool and Process Design •

ERC

NSM

© Copyright Engineering Research Center for Net Shape Manufacturing, 2005. All rights reserved. Slide 1

Research and Development in

Forging at ERC/NSM

Dr. Taylan Altan, Professor and Director, [email protected]

Ms. Linda Anastasi, Office Secretary, [email protected]

Center for Precision Forming (CPF)

Engineering Research Center for Net Shape Manufacturing (ERC/NSM)

Columbus, Ohio, USA

Phone: 614-292-9267, Fax: 614-292-7219

www.ercnsm.org & www.cpforming.org

ERC

NSM

© Copyright Engineering Research Center for Net Shape Manufacturing, 2005. All rights reserved.

ERC/NSM Webpage

Slide 2

ERC

NSM

© Copyright Engineering Research Center for Net Shape Manufacturing, 2005. All rights reserved.

Organization Structure

ERC/NSMThe Ohio State University

Dr. Taylan Altan, Professor and Director

Government agenciesDepartment of EnergyDepartment of DefenseNational Science Foundation

Individual companies from countriesU.S.A, Germany, Japan, FranceSpain, New Zealand, Canada

Graduate students

Students pursuing Masters and Ph.D degree at The Ohio state university

Visiting Scholars

Students pursuing Dipl-Ing and Ph.D degree at other universities in Europe

Slide 3

ERC

NSM


ERC/NSM Activities

Stamping Hydroforming MachiningForging

Research for Industry and Government

1) Material characterization <flow stress & formability>

2) Tribology < friction,lubrication & wear >

3) Process Modeling (FEA)/Tool and Process Design

4) Short Courses/Training for Industry and Students

ERC

NSM


ERC/NSM Activities

Stamping Hydroforming MachiningForging

Research for Industry and Government

ERC

NSM


ERC/NSM Activities in Forging

1. Materials Determination of material flow stress data by cylinder compression tests.

2. Tribology (Friction, Tool Wear) Performance evaluation of cold forging lubricants.

Die Failure (Wear/ Fracture) Prediction

3. Process Modeling / Tool and Process Design

• 3D Simulation of Aircraft Structural Components.

• Forging of Internal Combustion Engine Pistons from Aluminum Alloys.

• Multiple Action Cold Forging of Complex Shaped Parts

• Prediction and Reduction of Die Failure in Precision Hot Forging

• Simulation to Compare Surface Quality in Billet Shearing

• Improvement in Tool Life for Cold Header Tooling

• Prevention of Ductile Fracture (Chevron Cracks)

• Stress Analysis and Evaluation of the Bullet Crimping Process

• Three Dimensional Finite Element Simulation of Orbital Forming of Spindle/Bearing Assembly

• Microforming of Medical Devices

ERC

NSM


1.Materials/ Compression Test Tooling

Upper plate

Carbide inserts

Load-cell 1

(200 T)

Load-cell 2

(15 T)

Lower plate

ERC

NSM


1. Materials/ Deformed billets

Height

reduction =44.5%

Height

reduction =52%Height

reduction =62%Height

reduction =33%

Micrographs of side surface after deformation

0.01 mm

ERC

NSM


1. Materials/ Test Results

- Flow stress at different reductions -

Flow Stress Curves-As Received Begin

0

20000

40000

60000

80000

100000

120000

0 0.2 0.4 0.6 0.8 1 1.2Strain

Str

es

s (

psi)

Height reduction=33%

Height reduction=44.5%

Height reduction=52%

Height reduction=67%Reduction=33%

Reduction=44.5%

Reduction=52%Reduction=67%

ERC

NSM


1. Materials/ Test Results

- Flow stress Curve -

Flow Stress Curve

0

20000

40000

60000

80000

100000

120000

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7Strain

Str

ess (

psi)

From Experiment

From Equation

K= 117 Ksi, n=0.18 determined by least square fit

18.0117

ERC

NSM


Tribology (Friction, Tool Wear)

Performance evaluation of cold forging lubricants by the double

cup extrusion test.

Evaluation of alternative lubricants for replacement of zinc

phosphate coating based lubricants.

Wear and Fracture prediction using FEM simulation.

2. Tribology

ERC

NSM


2. Tribology/ Double Cup

Extrusion Tooling

Double cup extrusion tooling with lower punch at

its upper position for billet removal.

ERC

NSM


Double cup extrusion tooling (sectional view).

2. Tribology/ Double Cup Extrusion

Tooling

ERC

NSM


2. Tribology/ Test Results

Initial billet Formed billet

h1

h2

• Ranking the lubricants based on cup height ratio h1/h2

• Surface analysis is done on the cut specimen to investigate galling

• Coefficient of Friction can be determined

ERC

NSM


2. Tribology/ Tested Lubricants

Three lubricant candidates for replacement of zinc phosphate

coating based lubricants were tested.

• MEC Homat

• Daido

• Metal Coating International (MCI)

• Zinc Phosphate Coating ( Control lubricant )

ERC

NSM


2. Tribology/ Lubricant Performance

Friction factor obtained for different lubricants

0.035

0.075

0.068

0.04

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

Mec Homat MCI Phoscoating Daido

Lubricants

Fri

ctio

n fa

cto

r (m

)

ERC

NSM


2. Tribology/ Die Failure Prediction

• Die Wear (Abrasive)

• Archard’s Model:

• Behrens’ Model: vdtH(time)

PKW

a

dt(time)H

vPKW

c

ba

Where:

W= Amount of Wear

K= Process Wear Coefficient

P= Normal Pressure

v= Sliding Velocity

H= Hardness of the Die

dt= Time Interval

a, b, c= experimental constants

Current Work being done by:

Adam Groseclose, GRA ([email protected])

Dr. Changhyok Choi, Visiting Scholar ([email protected])

ERC

NSM


R

Z

2. Tribology/ Die Failure Prediction (Abrasive Wear)

ERC

NSM


2. Tribology/ Die Failure Prediction (Fatigue Fracture)

386MPaFatigue Fracture is predicted,

using Deform 2D, to be in the

same region as experimentally

determined.

The stresses of the region

were found to be tensile, which

would cause a fatigue loading

and eventual fracture.

• Die Fracture (Fatigue)

ERC

NSM


• 3D Simulation of Aircraft Structural Components.

• Forging of Internal Combustion Engine Pistons from Aluminum Alloys.

• Multiple Action Cold Forging of Complex Shaped Parts

• Prediction and Reduction of Die Failure in Precision Hot Forging

• Simulation to Compare Surface Quality in Billet Shearing

• Improvement in Tool Life for Cold Header Tooling

• Prevention of Ductile Fracture (Chevron Cracks)

• Stress Analysis and Evaluation of the Bullet Crimping Process

• Three Dimensional Finite Element Simulation of Orbital Forming of

Spindle/Bearing Assembly

• Microforming of Medical Devices

3. Process Modeling and

Development

ERC

NSM


Forging sequence for the aircraft wheel.

3. Process Modeling/

Simulation of Aircraft Wheel

Aida PPT\wheelstage1.avi

Aida PPT\wheelstage1.avi

Aida PPT\wheelStage2.AVI

Aida PPT\wheel finish.avi

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Simulation of Aircraft Wheel

Software: DEFORM 3D

Part: Aircraft Wheel

Size: Diameter – 560 mm;

Height – 216 mm

Stage: Preforming

Material: AA 2014

Initial Temperature:

• Dies = 700oF

• Billet = 700oF

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NSM


Forging sequence for an aircraft fitting.


Simulation of Aircraft Fitting

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NSM



Simulation of Aircraft Fitting

Software: DEFORM 3D

Part: Aircraft Fitting

Size: 28” x 4” x 4”

Stage: Preforming

Material: Ti – 6Al – 4V

Initial Temperature:

• Dies = 600o F

• Billet = 1750o F

ERC

NSM



Forging of an Automotive Component

Hot forging of an automotive component.

ERC

NSM



Simulation of Flashless Forging

Flashless forging of a connecting rod.

ERC

NSM


3. Process Modeling/ Forging of IC Engine Piston for Racing

Forging of a race-car Al alloy piston.

ERC

NSM


Cross groove inner race of a constant velocity joint.

3. Process Modeling/ Cold Forging Using Multiple Action Tooling

ERC

NSM


3. Process Modeling/ Cold Forging Using Multiple Action Tooling

ERC

NSM



Simulation of Billet Shearing

Billet shearing with element deletion.

ERC

NSM



3-D Simulation of Billet Shearing

ERC

NSM



Prediction of Chevron Cracks

Prediction of chevron cracks during forward extrusion.

ERC

NSM



Orbital Forming

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Orbital Forming

Stress contour during orbital forming.

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NSM



Micro - Forming

Microforming of cutting blades

(Part thickness = 0.1 mm; flash thickness = 0.01 mm ).

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Micro - Forming

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NSM


3. Process Modeling/ Assembly of Tubular Components by

Mechanical Crimping

Application to bullet crimping with a mechanical tool.

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NSM


Simulation of bullet pullout test (test of crimp quality).

3. Process Modeling/ Assembly of Tubular Components by

Mechanical Crimping

ERC

NSM


3. Process Modeling/ Assembly of Tubular Components by Hydraulic

Crimping

Application to bullet crimping with a rubber tool.

ERC

NSM


Simulation of bullet pullout test (test of crimp quality).

3. Process Modeling/ Assembly of Tubular Components by Hydraulic

Crimping

Documents

Research and Development in Forging at ERC/NSM evaluation of cold forging lubricants. Die Failure (Wear/ Fracture) Prediction 3. Process Modeling / Tool and Process Design •