Effect of nitrogen content on the microstructure and mechanical properties of titanium-bearing nonquenched and tempered steel after hot forging

The microstructure and mechanical properties of titanium(Ti)-bearing medium-carbon nonquenched and tempered steel with different nitrogen content before and after hot forging were investigated through smelting,forging,and laboratory tests.The results show that the grain size of nonquenched and tempered steel was gradually refined,and the ferrite content gradually increased with an increase in nitrogen content.The grain size of the material with low nitrogen content increased abnormally,and its impact properties significantly decreased after hot forging.The grain size of nonquenched and tempered steel with higher nitrogen content was slightly larger than that before forging,and the tensile and yield strength increased,but the impact toughness was not significantly reduced.The Ti-bearing nonquenched and tempered steel showed better strength and toughness after hot forging with the addition of 0.010%0.015%nitrogen.

基于Simufact Forging高铁轮毂锻压成形工艺仿真

基于Simufact Forging有限元分析软件对高铁轮毂成形过程进行了仿真,着重研究了轮毂辗扩过程中的等效塑性应变、等效应力及材料流动。结果表明:高铁轮毂在辗扩过程中材料整体变形基本一致,可以获得较好的力学性能;随着锻压成形不断的进行,轮毂内圈塑性应变逐渐变大;成形过程中整个轮毂应力分布较为均匀。

Review ： State-of-the-Art of Stamping-Forging Process with Sheet Metal Blank

The aim of this paper is to review the state-of-the-art SFPs and their applications,and to provide a guide for researchers and engineers working in this field.Various SFPs are classified according to the combination ways of stamping and forging operations.The process principle of each combination is reviewed,with its applications discussed.The state-of-the-art of SFPs suggests that future work in this field should focus on the development of high-strength die materials,better lubrication control methods,forming machines with intelligent control capacity and special functions,and some new SFPs for high strength or ultra-high strength materials.

Minimization of Stock Weight during Close-Die Forging of a Spindle

In this paper, Finite Element method and full-scale experiments have been used to study a hot forging method for fabrication of a spindle using reduced initial stock size. The forging sequence is carried out in two stages. In the first stage, the hot rolled cylindrical billet is pre-formed and pierced in a closed die using a spherical nosed punch to within 20 mm of its base. This process of piercing or impact extrusion leads to high strains within the work piece but requires high press loads. In the second stage, the resulting cylinder is placed in a die with a flange chamber and upset forged to form a flange. The stock mass is optimized for complete die filling. Process parameters such as effective strain distribution, material flow and forging load in different stages of the process are analyzed. It is concluded from the simulations that minor modifications of piercing punch geometry to reduce contact between the punch and emerging vertical walls of the cylinder appreciably reduces the piercing load. In the flange chamber, a die surfaces angle of 52° instead of 45° is proposed to ensure effective material flow and exert sufficient tool pressure to achieve complete cavity filling. In order to achieve better compression, it is also proposed to shorten both the length of the inserted punch and the die “tongues” by a few mm.

MICROSTRUCTURAL MODEL OF GATORIZED WASPALOY IN THE ISOTHERMAL FORGING PROCESS

A microstructural model, which was to predict the evolution of microstructure of Gatorized Waspeloy in the isothermal forcing process, was developed in terms of dynamic recrystallization and grain growth. Three steps of experiment were conducted during developing the model: (1) .Specimens were compressed in M FS testing machine; (2) Dynamic recrystallization and grain growth were discussed; (3) Dynamic recrys- tallization model and grain growth mode were set up. The agreement of simulated results and experimental data is fine.

NUMERICAL SIMULATION OF FORGING AND SUBSEQUENT HEAT TREATMENT OF A ROD BY A FINITE VOLUME METHOD

A method to simulate processes of forging and subsequent heat treatment of an axial symmetric rod is formulated in eulerian description and the feasibility is investigated. This method uses finite volume mushes for troching material deformation and an automatically refined facet surface to accurately trace the free surface of the deforming material.In the method,the deforming work piece flows through fixed finite volume meshes using eulerian formulation to describe the conservation laws,Fixed finite volume meshing is particularly suitable for large three-dimensional deformation such as forging because remeshing techniques are not required, which are commonly considered to be the main bottelencek in the ssimulations of large defromation by using the finite element method,By means of this finite volume method, an approach has been developed in the framework of "metallo-thermo-mechanics" to simulate metallic structure, temperature and stress/strain coupled in the heat treatment process.In a first step of simulation, the heat treatment solver is limited in small deformation hypothesis,and un- coupled with forging. The material is considered as elastic-plastic and takes into account of strain, strain rate and temperature effects on the yield stress.Heat generation due to deformation,heat con- duction and thermal stress are considered.Temperature - dependent phase transformation,stress-in- duced phase transformation,latent heat,transformation stress and strain are included.These ap- proaches are implemented into the commerical commercial computer program MSC/SuperForge and a verification example with experimental date is given as comparison.

Computer Aided Simulation on Precision Cold Forging of Universal Joint Cross

The 3D FEM numerical simulation on multi-action precision cold forging technology of universal joint cross and differential spider is done in this article using DEFORM Software, a commercial computer aided engineering software specializing in forming and heat treatment simulation technology, and suitable for cold, warm and hot forging process. The material flow properties, the dynamic variation of stress and strain in the process of deformation and the load-stroke curve have also been achieved. A good consistency is exhibited between simulation results and practical data. Based on the DEFORM simulation results, the optimized procedure has been found for forging a universal joint cross. What should be emphasized here is that a better understanding of practical forging characters and the environmental factors can greatly improve the simulation accuracy thus make the simulation results more reliable.

Numerical simulation on forging process of TC4 alloy mounting parts

In order to eliminate forging defects appearing in production,based on the rigid-viscoplastic FEM principle,the DEFORM3D software package was employed to simulate the forming process of TC4 alloy mounting part and to optimize the process parameters.In this simulation,the temperature dependency of the thermal and mechanical properties of material was considered.Based on the simulation,the metal flow and thermomechanical field variables such as stress and damage are obtained.The simulation results show that the forging defects are caused by improper die dimension and the optimized die dimension was proposed.To verify the validity of simulation results,forging experiments were also carried out in a forging plant.The forging experiments show that the optimized die dimension can ensure the quality of forging part,and it can provide reference to improve and optimize die design process.

Effect of pre-induced twinning on microstructure and tensile ductility in GW92K magnesium alloy during multi-direction forging at decreasing temperature

Effect of pre-induced twinning on the microstructure evolution and mechanical properties of extruded Mg-9.26Gd-2.08Y-0.36Zr(GW92K)alloy have been investigated during multi-direction forging with large strains at decreasing temperature from 400℃ to 300℃.The results showed that,whether there pre-induced twinning existing in the initial microstructure by pre-deformation or not,a mixed microstructure of residual coarse grains and notably refined grains formed under both conditions,combing with some residual coarse grains with less deformation inside grains and lots of dispersed nano-precipitates distributed along refined grain boundaries.However,a significant improvement with the tensile ductility was obtained by the pre-induced twinning in the former alloy.It was suggested that,the pre-induced twinning largely contributed to the grain refinement and lead to an increase in the ratio of fine grain structure which would be responsible for the better properties.Furthermore,during subsequent forging deformation in the pre-deformed sample,the grain refinement mechanism by gradual grain orientation rotation around the surface section in residual coarse-grains was a little different from that by the macro-shear deformation in the as-extruded condition.

Effect of Zn/Mg/Cu Additions on Hot Cracking Tendency and Performances of Al-Cu-Mg-Zn Alloys for Liquid Forging

During the process of liquid forging, a host of hot cracking defects were found in the Al-CuMg-Zn aluminum alloy. Therefore, mechanical tests and analyses by optical microscope, scanning electron microscope, and X-ray diffraction were performed to research the influences of zinc, magnesium, and copper(three main alloying elements) on hot cracking tendency and mechanical properties. It was concluded that all the three alloying elements exerted different effects on the performances of newly designed alloys. And the impact of microstructures on properties of alloys was stronger than that of solution strengthening. Among new alloys, Al-5 Cu-4.5 Mg-2.5 Zn alloy shows better properties as follows: σb=327 MPa, δ=2.7%, HB=107 N/mm^2, and HCS=40.

Achieving three-layered Al/Mg/Al sheet via combining porthole die co-extrusion and hot forging

Al/Mg/Al sheet with good bonding quality and mechanical properties was fabricated based on the proposed porthole die co-extrusion and forging(PCE-F)process.There were no voids,cracks or other defects on the Al/Mg interface.A continuous diffusion zone with two-sub-layer structure was formed across the Al/Mg interface,and its width increased with higher temperature or reduction ratio.The sub-layers formed at low and high temperature were identified to be solid solutions and intermetallic compounds(IMCs)including y-MgpAl^and^-Al3Mg.In Al layer,the welding zone mainly consisted of fine equiaxed grains with several coarse elongated grains,while the majority of matrix zone is coarse elongated grains.The rolling textures were dominated in both welding and matrix zones.In Mg layer,the welding zone exhibited complete DRXed grain structure,while several unDRXed coarse grains were observed in the matrix zone.With the increasing temperature,the grain size of Al and Mg layer firstly decreased and then increased.High reduction ratio strongly refined the grain structure of Al layer,while slightly affected the Mg layer.The Al/Mg/AI sheet experienced stress-drops twice during the tensile test.The first stress-drop was determined by the IMCs and microstructure of Mg layer,while the second stress-drop was closely related to the microstructure of Al layer.Al/Mg/Al sheet forged at the lowest temperature without the formation IMCs exhibited the highest stress for the first stress-drop,and that forged under the highest reduction ratio with the smallest grain size in Al layer had the highest stress for the second stress-drop.

Microstructural evolution of Mg-7Al-2Sn Mg alloy during multi-directional impact forging

Multi-directional impact forging(MDIF)was applied to a Mg-7Al-2Sn(wt.%)Mg alloy to investigate its effect on the microstructural evolution.MDIF process exhibited high grain refinement efficiency.After MDIF 200 passes,the grain size drastically decreased to 20µm from the initial coarse grains of~500µm due to dynamic recrystallization(DRX).Meanwhile,original grain boundaries remained during MDIF and large numbers of fine sphericalβ-Mg_(17)Al_(12) particles dynamically precipitated along the original grain boundaries with high Al concentration,acting as effective pinning obstacles for the suppression of DRXed grain growth.Besides,micro-cracks nucleated during MDIF and propagated along the interface between the remained globular or cubic Al-Mn particles and Mg matrix.

STRESS FIELD ANALYSIS OF EXTRA-HEIGHT FORGING DIE USING FINITE ELEMENT METHOD

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Ductility enhancement of EW75 alloy by multi-directional forging

In this study,the Mg-7Gd-5Y-1Nd-0.5Zr alloy can reach a high ductility by the process of multi-directional forging,and the evolution of the microstructure,texture and the mechanical properties were discussed systematically.The results show that after the solutionized sample was multi-forged at 500℃,its grain size can be refined from 292 um to 58 um.As the forging temperature decreased,fine particles precipitated in the matrix.The volume fraction of the particles increased with the forging temperature decreasing,so the nucleation and growth of crystallization were strongly restricted.There was no recrystallization as the forging temperature fell to 410℃,and the severe deformed grains distributed as streamlines perpendicular to the final compression axis.The texture intensity decreased with increasing forging passes.The sample with best ductility was obtained after compressed at 470℃,with an elongation to failure of 21%at room temperature,which is increased by 200%,in comparison with that of the samples in solutionized condition.EBSD results revealed that the mean grain size was 15 um.Refined grains as well as the weakened texture were the key factors to its high ductility.

Volume calculation of the spur gear billet for cold precision forging with average circle method

Forging spur gears are widely used in the driving system of mining machinery and equipment due to their higher strength and dimensional accuracy.For the purpose of precisely calculating the volume of cylindrical spur gear billet in cold precision forging,a new theoretical method named average circle method was put forward.With this method,a series of gear billet volumes were calculated.Comparing with the accurate three-dimensional modeling method,the accuracy of average circle method by theoretical calculation was estimated and the maximum relative error of average circle method was less than 1.5%,which was in good agreement with the experimental results.Relative errors of the calculated and the experimental for obtaining the gear billet volumes with reference circle method are larger than those of the average circle method.It shows that average circle method possesses a higher calculation accuracy than reference circle method(traditional method),which should be worth popularizing widely in calculation of spur gear billet volume.

Prediction of Grain Size for Blade Precision Forging Process under Thermo-Mechanical Coupling

Blade precision forging is a high temperature and large plastic deformation process. Interaction of deformation andheat conduction results in producing large temperature unevenness inside the billet. The unevenness has a greateffect on the mechanical property and microstructure of the forged blade. However, internal quality of the blade isdecided by its microstructure, it is necessary to conduct a research on the microstructure of the blade forging process.Taking a blade with a tenon as an object, its precision forging process is simulated and analyzed using a 3D coupledthermo-mechanical FEM code. And based on the prediction model of Ti-6Al-4V presented by the predecessor, astudy of the evolution of grain size in the forging process is made. The distribution characteristics of grain size intypical sections are obtained under various deformation degrees. This study may provide a base for designing theblade forging process and working out its parameters.

Impedance Analysis of Forging Process and Strategy Study on Compliance for Forging Manipulator

In the field of heavy forging, there are numerous researches on deformation rule in forging process by FEM simulation, however, not many scholars take the equipment constraint and the mutual reaction load between the forging manipulator clamp and the forging blank into account, which will impact on safety of manipulator body and quality of forging blank. This paper presents an impedance model to describe the load and formulates compliance strategies correspondingly to reduce the mutual reaction load for forging manipulator. Firstly, an FEM model of forging process is built. Meanwhile, the clamp of forging manipulator is added to the model as movement constraint and interaction part between the manipulator and the forming process. Secondly, a typical forging process is simulated by changing the movement constraint, and then an impedance model is established to describe the relationship between the load and movement constraint. Finally, two kinds of compliance strategies are formulated according to the impedance model, one is called free compliance, and the other is initiative/passive compliance. The simulation results show that compliance strategies reduce the load amounting to 5 000 kN in z direction between the manipulator clamp and the forging blank obviously, which may lead to serious accidents, such as the capsizing of forging manipulator, the fracture of manipulator clamp, and so on. The proposed research simulates the more real forging process, gets the initiative/passive compliance strategy which is more simple and suitable to the real producing and better for forming a forging process planning and control system in the modern production, and improves the quality and efficiency of heavy forging.

A two-step superplastic forging forming of semi-continuously cast AZ70 magnesium alloy

A two-step technology combined forging with superplastic forming has been developed to enhance the forgeability of semi-continuously cast AZ70 magnesium alloy and realize the application of the as-cast magnesium alloy in large deformation bullet shell.In the first step,fine-grained microstructure preforms that are suitable for superplastic forming were obtained by reasonably designing the size of the initial blanks with the specific height-to-diameter ratio,upsetting the blanks and subsequent annealing.In the second step,the heat treated preforms were forged into the end products at the superplastic conditions.The end products exhibit high quality surface and satisfied microstructure.Consequently,this forming technology that not only avoids complicating the material preparation but also utilizes higher strain rate superplastic provides a near net-shaped novel method on magnesium forging forming technology using as-cast billet.

Microstructure,texture evolution and yield strength symmetry improvement of as-extruded ZK60 Mg alloy via multi-directional impact forging

Multi-direction impact forging(MDIF)was applied to the as-extruded ZK60 Mg alloy,and the microstructure,texture evolution and yield strength symmetry were investigated in the current study.The results showed that the average grain size of forged piece was greatly refined to 5.3μm after 120 forging passes,which was ascribed to the segmenting effect of{10–12}twins and the subsequent multiple rounds of dynamic recrystallization(DRX).A great deal of{10–12}twins were activated at the beginning of MDIF process,which played an important role in grain refinement.With forging proceeding,continuous and discontinuous DRX were successively activated,resulting in the fully DRXed microstructure.Meanwhile,the forged piece exhibited a unique four-peak texture,and the initial<10-10>//ED fiber texture component gradually evolved into multiple texture components composed of<0001>//FFD(first forging direction)and<11–20>//FFD texture.The special strain path was the key to the formation of the unique four-peak texture.The{10–12}twinning and basal slip were two dominant factors to the evolution of texture during MDIF process.Grain strengthening and dislocation strengthening were two main strengthening mechanisms of the forged piece.Besides,the symmetry of yield strength was greatly improved by MDIF process.

Dynamic precipitation during multi-axial forging of an Mg-7Gd-5Y-1Nd-0.5Zr alloy

The dynamic precipitation behavior during multi-axial forging in an Mg-7Gd-5Y-1Nd-0.5Zr alloy has been investigated and compared with that in static precipitation treatment. The results indicated that dynamic precipitation does occur during multi-axial forging. The dynamic precipitate can be deduced as β phase with face-centered cubic crystal structure (a = 2.22 nm). Most of the β precipitates locate at the dynamic recrystallization grain boundaries. The morphology and orientation relationship is different from that of the β phase formed in the static precipitation treated alloys, although the crystal structure is the same. The precipitation temperature of β phase during MAF is higher than that in the static precipitation treatment.