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An additional hemisphere forging was done which failed prematurely. A combination of mechanical testing and forging are utilized to investigate both the flow and fracture processes involved. The deformation processes involved in the forging of refractory ceramic oxides were investigated. It is significant to increase the practical production of enterprise, especially to reduce the production cost and to promote enterprise profit.ĭeformation processes in forging ceramics Through the analysis of experimental results, the best forging process parameters were optimized and determined, which could effectively reduce the die wear and prolong the die service life. Based on the Archard wear model, the influences of billet temperature, die temperature, forming speed, top die hardness and friction coefficient on forming load and die wear were numerically simulated by DEFORM software.
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S.įor the forging process of the swash plate, the author designed a kind of multi-index orthogonal experiment. Multi-objective optimization of swash plate forging process parameters for the die wear/service life improvement This work suggests that the processing parameters can be optimized to prepare a connecting rod with uniform density distribution and can help to better meet the requirements of the connecting rod industry. The optimum forging processing parameters were determined and presented by using an orthogonal design method. Moreover, the relative density of the connecting rod was sensitive to the processing parameters such as the forging velocity and the initial density of the preform. The results showed that the relative density of the hot forged connecting rod at the central shank changed significantly compared with the relative density at the big end and at the small end. The relationship between the processing parameters of hot forging and the relative density of the connecting rod was revealed.
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The calculated results agree well with the experimental results.
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The deformation behaviors of a connecting rod preform, a Fe-3Cu-0.5C (wt pct) alloy compacted and sintered by the powder metallurgy route (PM Fe-Cu-C), were investigated using the finite element method, while damage and friction behaviors of the material were considered in the complicated forging process. The densification behaviors of powder metallurgy (PM) connecting rod preforms during hot forging processes play a significant role in optimizing the connecting rod quality. Powder forged connecting rods have the problem of non-uniform density distributions because of their complex geometric shape. Li, Fengxian Yi, Jianhong Eckert, Jürgen Optimization of the Hot Forging Processing Parameters for Powder Metallurgy Fe-Cu-C Connecting Rods Based on Finite Element Simulation The developed method is demonstrated by applying it to an axisymmetric H-cross section disk forging to improve the product quality and robustness. Finally, a Robust Methodology is developed to optimize forging process parameters and preform shape. Variability in system performance due to randomness in the parameters is computed by applying Monte Carlo Simulations (MCS) on generated Response Surface Models (RSM). Since the forging process simulation is computationally intensive, the response surface approach is used to reduce time by establishing a relationship between the system performance and the critical process design parameters. In this paper, various uncertainties that affect forging tool life and preform design are identified, and their cumulative effect on the forging process is evaluated. Identifying the sources of uncertainties, quantifying and controlling them will reduce risk in the manufacturing environment, which will minimize the overall cost of production. A combination of these uncertainties could induce heavy manufacturing losses through premature die failure, final part geometric distortion and production risk. Optimum Design of Forging Process Parameters and Preform Shape under Uncertaintiesįorging is a highly complex non-linear process that is vulnerable to various uncertainties, such as variations in billet geometry, die temperature, material properties, workpiece and forging equipment positional errors and process parameters.