Analysis of roll-forging process

Karacaovalı, Hakan
Roll-forging is a metal forming process and mainly used for preform forging of long parts prior to press or hammer forging in the industry. Variable cross sections through the length of billet can be obtained by roll-forging to acquire an adequate distribution of material to the next forging stages. In the design of process and dies used in roll-forging, there are some empirical techniques in literature. However these techniques only provide approximate reduction ratio and elongation during the process and the geometry of the workpiece at the end of each stage cannot be determined exactly by using these techniques. In this study, multistage roll-forging process has been analyzed by using a finite element analysis software to examine material flow, temperature, stress and strain distribution at each roll-forging step. The geometries at the intermediate stages have been determined. Computer results have been compared to experimental results and good agreement has been observed.


Analysis of warm forging process
Aktakka, Gülgün; Darendeliler, Haluk; Department of Mechanical Engineering (2006)
Forging is a metal forming process commonly used in industry. Forging process is strongly affected by the process temperature. In hot forging process, a wide range of materials can be used and even complex geometries can be formed. However in cold forging, only low carbon steels as ferrous material with simple geometries can be forged and high capacity forging machinery is required. Warm forging compromise the advantages and disadvantages of hot and cold forging processes. In warm forging process, a product...
Experimental and numerical analysis of compression on a forging press
Biçer, Gökhan; Gökler, Mustafa İlhan; Department of Mechanical Engineering (2010)
Forging is a metal forming process which involves non-linear deformations. Finite element and finite volume software programs are commonly used to simulate the process. In these simulations, material properties are required. However, stress-strain relations of the materials at some elevated temperatures are not available in the material libraries of the related software programs. In this study, the stress-strain curves have been obtained by applying the Cook and Larke Simple Compression Test to AISI 1045 st...
Design of fixturing system for forging dies
Cavbozar, Özgür; Gökler, Mustafa İlhan; Department of Mechanical Engineering (2008)
In forging industry, the die setup starts with unloading the previous die set and ends with approval of the first part produced. During conventional die setup, forging press is kept idle. The aim of this study is to perform die changing applications of the 1000 ton forging press of Aksan Steel Forging Company in more systematic way to reduce the idle time. The applicability of Single Minute Exchange of Dies (SMED) System and quick die locating methods have been studied. SMED classifies the setup operations ...
Analysis of tube upsetting
Tüzün, Aydın; Darendeliler, Haluk; Department of Mechanical Engineering (2004)
Producing axi-symmetrical parts with holes from tubular stock by tube upsetting is a frequently used technique in industry. There are basically four types of tube upsetting process; external, internal, simultaneous internal and external upsetting, and expanding of tube. In general, tubular parts require more than one upsetting stage. In industry, generally trial-error methods, which require lots of time and effort depending on experience, are used for the design of stages. Wrong design causes failures durin...
Analysis of heat treatment effect on springback in v-bending
Sarıkaya, Onur Turgay; Darendeliler, Haluk; Department of Mechanical Engineering (2008)
Aluminum based alloys have wide area of usage in automotive and defense industry and bending processes are frequently applied during production. One of the most important design criteria of bending processes is springback, which can be basically defined as elastic recovery of the part during unloading. To overcome this problem, heat treatment is generally applied to the workpiece material to refine tensile properties. In this study, the effect of heat treatment on springback characteristics of aluminum stud...
Citation Formats
H. Karacaovalı, “Analysis of roll-forging process,” M.S. - Master of Science, Middle East Technical University, 2005.