BLOCKING DIE IMPRESSION SHAPE DESIGN USING COMPUTER SIMULATION

Mria KAPUSTOV Miroslava KOLOV

Abstract: The aim of the paper is focus on the importance of simulation software for material flow monitoring in the impression of die. The simulation proves to detect the possible mistakes of material flow. It is possible by adjusting of tool geometry to eliminate mistakes in preliminary phase of forged production, what presents production costs savings. Using of simulation software has big importance for successful development of new unconventional technologies in production praxis, because essentially reduces economical severity of proving processes. Key words: closed die forging, simulation, blocking impression of die, finite volume method

lower material and energy consumption. In term of material savings is interested closed die forging technology without flash space, what however requires to put right technological parameters of forge. The quality, performance and life of die are the most decisive criteria of the design, optimization and application of closed die forging for the prediction of forged pieces and therefore it is needed to determine impression shape of tool. In loading of precision die forging method into production praxis has big consequence computer simulation of technological process, which enables to understand forging process and plastic flow of material in die impression during its filling. So that are very quickly diagnostic mistakes of bad flow, or not filling places in die impression, whether big flash, what signalizes abnormal consumption of material. Simulation software allows to optimization dimensions of billet, shape of forging blank, whether final shape of tool impression and so eliminate mistakes in prepare phase of production. For process simulation of die forging were developed different simulation programs such DEFORM, FORM2D, QFORM3D,FORGE3,MSC.SuperForge,MSC.SuperForm and others, they use final element method (FEM), what is based on dividing of forming volume for finite final of simple geometrical shapes, eventually programs use finite volume method (FVM), where is calculated material flow by help of constant volume elements and there is not needed remeshing. The process of forging is highly nonlinear, for forging process is typically big material transfer and therefore has FVM method application in 3D simulation of forging.

3. SHAPE AND PRODUCTION OF FORGED PIECE 3.1 Raw material

Die forged Wheel has simple rotate shape, it is hollow, it has punched hole. It uses such gear wheel in gearboxes for agriculture and industry machines. Raw material for forged is bar round section with diameter 65 of steel 16NiCr4 with strength 830MPa. It is usually delivered without heat treatment, soft annealed and normalizing. It is dedicated for cementing and has good hot formability and good workability. It uses for very stressed mechanical components with cemented surface and higher strength and toughness in nucleus, for example gear wheels of gearboxes, spine shafts, wheels of differentials, especially stressed shanks, shafts of driving gears and so similar. Chemical composition of steel 16NiCr4 is in table1. Tab.1 Chemical composition of steel 16NiCr4 (wt.%)
Contents of elements min max chemical composition (wt.%)

1. INTRODUCTION
Computer technique in forming area allows to apply in all stages of production processes designing in forming, such also at production of forged pieces. The present market offers relative high quality simulation programs, what have wide application in verification of technological method accuracy. They become quickly integral member of design and all development process, because they provide in relatively short time to obtain optimal alternative of production and so to eliminate economically and time demanding experiments. The advantage of technological process simulation is realization of experiments out of real object, without real incidence to the production operations.

Material

2. CONSEQUENCE OF SIMULATION PROGRAMMS FOR CLOSED DIE FORGING

Dynamical improvement of operating production and competitiveness of our die forges may assure only precision die forging methods, which represent lucrative production of forged parts. They are source of higher quality of final product, what achieves by the method of 16NiCr4

C 0,13 0,19 Cr

Mn 0,7 1,0 Ni 0,8 1,10

Si

S 0,03 Ti

0,4 0,03 M o 0,1 Al 0,02 0,04

min max

0,6 1,0

0,01 33

3.2. Technological process of forged production

Required forged shape Wheel is obtained by closed die forging. Closed die forging appertains into advanced technology of forging, which make possible to produce forged parts with high precision of dimensions and surface quality. There is required precision volume of blank and precision dividing of material in blocking operations. Closed die forging has these main advantages: decrease material consumption about 15 until 25%, that is weight of flash decrease of forging forces about 30 until 40%, because there is diminished surface of forged about surface of land possibility of cant decreasing until zero with using of ejector possibility of fillet radius decreasing to achieve higher accuracy of forged, it does not rise displacement of forged Disadvantages of forging in closed die are heat in protective atmosphere, eventually using of induction heat, that minimal the scales. It is no possible to applied this method of forging for all shapes of forged parts, eventually it is needed shape modification. By closed die forging technology is no possible to forge on optional devices. In term of forging technology without flash is very important correct choice of type and compensator location of little material overflow in impression of closed die. For round shape of die forged Wheel was suggested redundant material compensation method into internal flash. It is necessary to order bars with higher precision, eventually sizing them on own devices. At forging in closed die is required precision dividing of material. For dividing of material is suitable saw of type Individual 510.330 GA, what make possible higher quality of cutting shape. Round shape bars 65 is needed to cut for stock with weight batch 2,68 0,03kg, informative length of stock is 103 mm. For production of round shape forged was suggested forging press type LZK2500 and forging process consists of three stages: to heat billet on upper forging temperature 1150C 1200 C upset billet into height 40mm to block the shape in blocking die impression to finish forged shape in impression of closed die Technological forging process of forged Wheel is in Fig.1. Final shape of forged is possible to obtain after punching of wad, what represent technologically needed scrap. Neat weight of forged is 2,54 kg.

4. OPTIMIZATION OF BLOCKING IMPRESSION SHAPE BY HELP OF SIMULATION SOFTWARE SUPERFORGE

Software MSC. SuperForge appertains into CAE systems, what are dedicated for computer simulation of 2D and 3D processes of die forging with using of method FEM or FVM. It is modern simulation software with easy attendance, which makes possible import CAD geometry in STL format. The simulation of processes of hot forming employ elastic-plastic model of material flow. The big software advantage is large material database, which is created with consideration upon dependence of material hardening, temperature and deformation velocity. In preliminary stage the simulation requires to define process of die forging, to insert model of tool, to choose material from database and forming machine, choice friction and temperature conditions for billet and tool. Output effect of this program is tracing all behavior of plastic material flow in die impression, deformation mesh in forming. The simulation software enables color display of flow velocity of material, values of strains, values of stresses in forming material and contact presses of tool surface on the end of simulation and backward during all behavior of forging too. This software was used in forging simulation of die forged Wheel. The mainly simulation setting of forged production simulation process: hot forging in closed die choice of FVM method insert 3D model of blocking die choice of machine: mechanical press LZK 2500 material of billet: DIN 1.7131 material of die: steel H13 billet temperature: 1150C die temperature: 250C friction coefficient: 0.25 After billet upsetting was monitored behavior of material in blocking die impression. It was simulated various options of blocking impression modification. At options with placing of wad in low side of die, the simulation predicted creation of lap and it was necessary to approach to modification impression shape of blocking die. On the Fig.2 and Fig. 3(a) is presented incorrect material flow during material filling of die impression.

Fig.2 Incorrect material flow during forging in closed blocking die Fig.1 Model of die forging WHEEL a shape of forged piece with wad and conical compensator, b forged piece after punching of wad, c shape of final forged piece 34 In Fig. 3(b) is traced lap, what was created during forging simulation. In figure is the lap placed in lower part of forging blank.

forging blank are presented in Fig.7. The values and behavior of effective plastic strain are presented in Fig. 8

(a)

(b)

Fig.3 Incorrect material flow during forging a) the end of simulation b) tracing of lap In Fig.4 is presented incorrect shape of forging blank with lap.

Fig.7 Effective stress of forging blank Model of blocking die created by software CATIA and imported into simulation program is in Fig. 9. The model is presented in section. Fig.4 Incorrect shape of forging blank The designing of blocking impression shape modification affords to visual change of forging blank shape. The wad was placed into the middle of die impression, the nose of punch was fillet with radius R4. The impression of die was correctly filled and the lap did not form. It was obtained by simulation forging blank shape without defects.

Fig.8 Effective plastic strain of forging blank Fig.5 Correct material flow during forging in closed blocking die In Fig. 5 is presented correct filling of die impression, it was used modified geometry of tool. The consequence and main reason of using of numerical process in proposition of forging method is development of adequate tool and verification of parameters by help of process simulation.

Fig.6 Correct shape of forging blank In Fig.6 is presented correct shape of forging blank without defects. The output effect from simulation was acquirement apart from view of material flow also colour presentation of material velocity, values of strains, values of stresses in forming material. The values of stress of

Fig.9 Model of blocking die Practical using of this method is possible to summarize: following of impression tool filling 35

prediction and elimination of flow material defects, as are laps, shrinks, detection of air pockets throughout forging process prediction and restraint of surface defects creation monitoring of stresses and strains throughout forging process, acquirement of importance information about forging process

5. CONCLUSION
The advantageous of process optimisation of die forging by help of computer simulation is obtaining a lot of information about follow up forming process in a short time. The aim of the article is mention on actual trends, tendencies and perspectives of further development of closed die technology, what presents lower production cost and they redound into higher competitiveness of our forges. In loading of precision forging method in praxis have big consequence simulation programs. They afford information, what are needed for followed optimisation of impression shape of forging tool and so to eliminate the mistakes in prepare phase of forged production. This paper was created thanks to the national grants: VEGA 1/3192/06 and KEGA 2006 3/416/06

CORRESPONDENCE
Mria Kapustov, MSc. Eng., PhD. Slovak University of Technology Faculty of Materials Science and Technology Paulnska 16 917 24 Trnava, Slovak Republic [email protected] Miroslava KOLOV, MSc. Eng. Slovak University of Technology Faculty of Materials Science and Technology Paulnska 16 917 24 Trnava, Slovak Republic [email protected]

REFERENCES
Books [1] BAA, J. Objemov tvrnenie. Zpustkov kovanie. Bratislava: MtF STU, 2005, s. 157. ISBN 80-227-2176-X Conference articles [2] INK, P., VAJO P. Optimalizcia parametrov kovania pre zvenie presnosti zpustkovch vkovkov. In TECHNOLGIA 97. Bratislava: SjF STU, 1997, s. 769774 [3] Kapustov, M., Blik, J. Vyuitie vpotovej techniky v oblasti tvrnenia. In Trendy technickho vzdelvan 2000, Olomouc, s. 161-164

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