Design of new die holder system for reducing die exchange time on 1000 ton hot forging press

Download

index.pdf

Date

2014

Author

Siddique, Muhammad Ahmad

Metadata

Show full item record

Item Usage Stats

262
views

111
downloads

In the forging industry, one of the main challenges is the reduction of setup change time which is non-productive time on the forging press. Long non-productive time reduces efficiency and affects profitability of the forging companies. In this thesis study, firstly setup change activities on the 1000 ton forging press of a forging company are observed and analyzed. With the help of these observations, it is seen that the new die holders with cassette holders and the new cassettes are required to reduce the setup change time radically. Different design versions of the new die holders have been studied. A new pair of die holders is designed and manufactured along with the new cassette holders and the new cassettes which hold the forging dies. The factors related to internal setup change operations, which are identified during the time and motion studies and root cause analysis, have been considered during design of the new die holder system. Several motion and time studies have been conducted to determine the average setup times for usage of new system. The average setup times for the new die holders and the previous die holders used in the particular forging company are compared and considerable reduction in setup time has been achieved. The time spent in mounting and aligning the die-cassette pairs on the die holders is significantly reduced during setup change by the help of the new die holder design. The motion and time study is concentrated on the internal setup change activities other than heating of the dies and cleaning of the forging press. By considering this way, 84% of reduction for the internal setup change time for the die holders with 2 die-sets and 62% of reduction for the internal setup change time for the die holders with 3 die-sets have been achieved on average.

Subject Keywords

Forging., Dies (Metal-working)., Forging industry.

URI

http://etd.lib.metu.edu.tr/upload/12618419/index.pdf
https://hdl.handle.net/11511/24362

Collections

Graduate School of Natural and Applied Sciences, Thesis

Suggestions

OpenMETU
Core

Analysis and preform design for long press forgings with non-planar parting surfaces Karagözler, Ahmet Barış; Gökler, Mustafa İlhan; Darendeliler, Haluk; Department of Mechanical Engineering (2003) In industry, a wide variety of parts are produced by press forging. Press forging generally requires sequential forming of workpieces through a set of preforming stages before the final stage. The design of preform dies affects die and product cost and quality. To ensure complete filling of the die at the final stage, companies in the forging industry commonly add extra material to the original workpiece volume and accordingly design the perform dies by the help of their experience. However, this method ref...
Analysis of forging for three different alloy steels Civelekoğlu, Barış; Darendeliler, Haluk; Gökler, Mustafa İlhan; Department of Mechanical Engineering (2003) Forging is a manufacturing process which is preferred among the others in that, the final product shows more enhanced properties. The properties of the final product are directly related with the material used in the forging process. Main parameters such as forging temperature, number of stages, preform design, dimensions of the billet, etc. may be affected by the forging material. Alloys are one of the main areas of interest in the forging industry. The use of alloy steels may bring superior properties, es...
Analysis of tapered preforms in cold upsetting Gökler, Mustafa İlhan; Darendeliler, Haluk (1999-01-01) Upset forging is usually carried out with a sequence of stages and the tapered preforms are commonly used. The preforms should be free from flash formation and buckling injuries. :In this paper, the results that depend on elastic-plastic finite element analysis of taper upset forging are given. The buckling analysis was realized by using the Modified Riks method. For a given upset ratio which is the ratio of unsupported length to diameter of the initial billet, reduction in the height of the billet and the ...
Variation of back-calculated breakage rate parameters in Bond-mill grinding Hoşten, Çetin; Avsar, C (Wiley, 2004-10-01) The variation of breakage rates with grinding environment is important in the analysis and simulation of various grinding processes. In particular, computer simulation of the labor-intensive experimental Bond grindability test requires reliable estimates of breakage rate and distribution parameters from a minimum amount of experimental work. This paper was aimed at studying the variation of breakage rate parameters in the Bond mill. Batch kinetic experiments with monosize feeds and standard locked-cycle Bon...
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 ...

Citation Formats

M. A. Siddique, “Design of new die holder system for reducing die exchange time on 1000 ton hot forging press,” M.S. - Master of Science, Middle East Technical University, 2014.