Apresentação do PowerPoint - sixpro.pro · Têmpera e Revenimento 6,6% 6,6% não considerado...

Preview:

Citation preview

Important Aspects

Forging Prediction

Rodrigo Lobenwein – Commercial

Alisson Duarte – Engineering

May 21st, 2018

SIXPRO Virtual&Practical Process

contato@sixpro.pro / www.sixpro.pro

• Material Properties

• Heat Treatment

• Forging

• Extrusion

• Rolling

• Wire drawing

• Sheet Metal Forming

2

Agent in Brazil

Agent in South America

SG PROJETOS

Center for Precision FormingOSU/The Ohio State University

Partners:

3

Furnace

Rammer

Ram

Forging

Furnace

Billet

Exit ramp

Rammer

Preform

Ram

Upper Die

Lower Die

4

Flange

5

Dies:• Material;• Temperature;• Wear;• Plastic deformation;• Elastic deformation;• Fracture.

Interface Die/Material:• Friction;• Heat exchange;• Lubrication;• Part residue.

Material;• Mechanical properties;• Temperature distribution;• Oxidation;• Final form and dimensions;• Fracture;• Phase transformation.

Presses;• Equipment;• Velocity;• Force.

Important Aspects

6

FEM Mesh

7

Node

Element

Billet being upset

Mesh Density

8

Engineering Curve

True stress/strain curve

Yield Stress= 300 MPa

oA

FT =

o

o

L

LLe

−=

constant

constant

Engineering

A

F=

=

0

lnL

L

True

Strain

Str

ess (

MP

a)

9

Material

Elastic portion

Flow Curve

Strain

Str

ess (

MP

a)

Flow Curve

10

Billet

Upper

Die

Bottom

Die

FEM Model

11

Interface problems Proper relationship

between part and die

Mesh Influence

12

Punch stroke (mm)

Forg

ing

Loa

d (

ton)

Effect on the Results

13

Symmetry plane

Symmetry plane

Points for profile measurement

Precision Gears

14

Normalized Cockroft and Latham 𝜖𝑒𝑓𝑖:𝜖𝑒𝑓𝑖 𝜎1

𝜎𝑒𝑓𝑑𝜀𝑒𝑓

Oyane:𝜖𝑒𝑓𝑖𝜖𝑒𝑓𝑖(1 +

𝜎𝑚

𝜎𝑒𝑓)𝑑𝜀𝑒𝑓

Ayada:𝜖𝑒𝑓𝑖𝜖𝑒𝑓𝑖 𝜎𝑚

𝜎𝑒𝑓𝑑𝜀𝑒𝑓

Normalized C&L

Fracture (Damage)

15

Inicial

50.000 Golpes

100.000 Golpes

150.000 Golpes

Number of

forged parts

Die Wear

16

17

Hammer Forging

Symmetry line

Process

18

Symmetry line

Simulation

19

Effective Strain

Effe

ctiv

e St

ress

(M

Pa)

Effect of Temperature

20

True Effective Strain

Engineering Effective Strain

Effective Strain

21

Chemical Composition

22

Taking into account the Processing History

23

Tensile Test

Forging

Effective Strain

Effe

ctiv

e St

ress

(M

Pa)

Effect of Strain Rate

24

Strain Rate (s-1)

25

Burr formation lineCentral region of thickness “t”

26

Heavy Forged Part

27

Preforming

(a)

Central region of thickness “2t” impossible to cut

Burr formation line

Possible defect (underfill)

Underfill

28

Problem

29

Results

30

Simulation – New Preform

31

Forged Geometry

Anterior Novo

Matéria Prima 30,5% 24,0% volume

Cortar 1,4% 1,4% não considerado

Forjar/Rebarbar 18,9% 5,1% quatidade de golpes

Usinagem central 12,9% 0,0% tempo de usinagem

Têmpera e Revenimento 6,6% 6,6% não considerado

Jatear 0,4% 0,4% não considerado

Usinagem acabamento 29,4% 29,4% não considerado

Total 100,0% 66,7%

Redução

considerada

Custos relativos (%)OperaçãoOperation

Relative costs (%)

Before New

Considered Reduction

Raw material

Piercing

Forging/Deburring

Central Machining

Quenching and Tempering

Shoot peening

Finishing machining

Volume

Not considered

Blow Number

Machining Time

Not considered

Not considered

Not considered

32

Costs

Tentativa Solução AbordagemPeso do

tarugo (kg)

Espessura

central (mm)

Margem de

lucro (%)Resultado Justificativa

1Pré-forma

cúbica

Tentativa

e erro30,0 12 - Impossível

Falta de

preenchimento

2Aumento no

volume

Tentativa

e erro38,5 25 - 1 Inviável

Aumento no volume

e na usinagem

3Modificação

da pré-formaSimulação 30,0 0 + 13 Viável

Redução no volume

e na usinagem

Attempt Solution ApproachBillet

Weight (Kg)Central

thickness (mm)

Profit Margin

Result Justification

Cubic Preform

Volume increase

Preform modification

Trial and error

Trial and error

Simulation

Impossible

Not viable

Viable

Underfill

Increase in the volume and machining

Reduction in the volume and machining

33

Viability

Numerical Method

Material Science

Fabrication Process

Process Simulation

Cost Analysis

Implementing Simulations

34

35

Thank you!

SIXPRO Virtual&Practical Process

contato@sixpro.pro / www.sixpro.pro

© Copyright SIXPRO Virtual&Practical

Process (6Pro). All Rights Reserved.

Recommended