Process-chain simulation of manufacturing of aerospace bearings

Date

2025-2

Author

Özgeneci, Zeren

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The hot forging process is crucial in the manufacturing chain of aerospace bearings. Materials used in bearing production typically experience significant deformation during hot forging, which leads to damage evolution. This evolution can impact both the material and the process, ultimately affecting the final product’s properties. In this study, hot compression tests were performed on the Gleeble 3800 to accurately obtain the material behaviour of M50 steel. Afterward, hot tensile tests were performed through experiments and simulations using Forge NxT 3.2® software to determine the triggering value for the normalized Latham-Cockcroft (LCn) damage criterion. Subsequently, the metallurgical basis for the determined LCn damage criterion was elucidated through detailed microstructural examinations, using optical microscopy and, primarily, scanning electron microscopy. Finally, based on the calculated LCn criterion value, a simulation of the multi-stage hot forging process, which includes upsetting, closed-die forging, and the shearing stage to separate the rings, was executed using Forge NxT 3.2®. This present study specifically focused on the third stage of the hot forging process: shearing, where achieving a precise and smooth cut surface is essential. Initial simulations of the multi-stage hot forging process were conducted using various die clearances and forging start temperatures, followed by evaluations with different tool speeds. To assess the impact of die geometry on the shearing stage, radii and conical shapes at various angles were incorporated into the tool edges in contact with the die corners. Additionally, hot forging was performed experimentally in the field to corroborate the simulation results.

Subject Keywords

M50 steel, Hot forging, Damage, Finite Element Method, Normalized Latham-Cockroft Criterion

URI

https://hdl.handle.net/11511/113524

Collections

Graduate School of Natural and Applied Sciences, Thesis