Design and thermo-mechanical analysis of warm forging process and dies

Saraç, Sevgi
Forging temperature is one of the basic considerations in forging processes. In warm forging, the metals are forged at temperatures about the recrystallization temperature and below the traditional hot forging temperature. Warm forging has many advantages when compared to hot and cold forging. Accuracy and surface finish of the parts is improved compared to hot forging while ductility is increased and forming loads are reduced when compared to cold forging. In this study, forging process of a part which is currently produced at the hot forging temperature range and which needs some improvements in accuracy, material usage and energy concepts, is analyzed. The forging process sequence design with a new preform design for the particular part is proposed in warm forging temperature range and the proposed process is simulated using Finite Element Method. In the simulations, coupled thermal mechanical analyses are performed and the dies are modeled as deformable bodies to execute die stress analysis. Experimental study is also carried out in METU-BILTIR Center Forging Research and Application Laboratory and it has been observed that numerical and experimental results are in good agreement. In the study, material wastage is reduced by proposing using of a square cross section billet instead of a circular one, energy saving and better accuracy in part dimensions is achieved by reducing the forging temperature from the hot forging to the warm forging temperature range.


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Halisçelik, Murat; Darendeliler, Haluk; Department of Mechanical Engineering (2009)
Semi-hot or warm forging is an economical alternative to the conventional forging processes by combining advantages of hot and cold forging processes. In this study, a new forging process sequence and design of the preform die for a part which has been produced by hot forging are proposed to be produced by semi-hot forging. Thermo-mechanical finite element analyses are performed over the stages of forging process. The billet and the dies are modeled as elastic-plastic bodies. Effects of preform die geometry...
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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...
Fatigue life calculation by rainflow cycle counting method
Arıduru, Seçil; Çalışkan, Mehmet; Department of Mechanical Engineering (2004)
In this thesis, fatigue life of a cantilever aluminum plate with a side notch under certain loading conditions is analyzed. Results of experimental stress analysis of the cantilever aluminum plate by using a uniaxial strain gage are presented. The strain gage is glued on a critical point at the specimen where stress concentration exists. Strain measurement is performed on the base-excited cantilever beam under random vibration test in order to examine the life profile simulation. The fatigue analysis of the...
Effects of induction heating parameters on forging billet temperature
Durukan, İlker; Gökler, Mustafa İlhan; Department of Mechanical Engineering (2007)
Induction heating is one of the efficient and modern technique for heating raw materials for hot forging process. The induction heating furnaces use electro-magnetic field to transfer energy to the metal workpiece and heat is generated inside the material. The magnetic field can be provided by using induction coil. The power supplied to induction coil, the moving speed of the billet that is called conveyor speed and the coil box hole diameter are the factors affecting the resultant temperature of the heated...
Citation Formats
S. Saraç, “Design and thermo-mechanical analysis of warm forging process and dies,” M.S. - Master of Science, Middle East Technical University, 2007.