Abstract
During the conventional disk-forging, the upper die repeatedly compresses materials on the flat stationary base. As the strain distributions of the forged disk are non-uniform owing to friction and uneven temperature distribution, more uniform deformation within the entire volume is desirable to obtain sound disk free from defects. This study proposes an advanced disk-forging process in the production of a defect-free heavy disk using counteracting dies. An industry-applicable disk-manufacturing process using a conventional single die-forging process and a proposed counteracting die were characterized and compared based on variations in geometries with successive forging steps. Variations in stress, equivalent strain, and temperature were obtained through three-dimensional finite element simulations using FORGE™ software, during the disk-forging processes of cylindrical preforms. Comparison of the simulation results indicated that the proposed forging process using counteracting dies was highly effective in producing sound disks having uniform microstructure without process-induced defects. The shop-floor production was performed to validate the proposed process, and the feasibility of the process was demonstrated based on the forged disk qualities that were assessed by non-destructive examination and mechanical testing. The test data showed that the defect-free disk with uniform mechanical properties was successfully produced through the proposed forging process using counteracting dies.
Similar content being viewed by others
References
Alabort E, Reed RC, Barba D (2018) Combined modelling and miniaturised characterisation of high-temperature forging in a nickel-based superalloy. Mater Des 160(15):683–697. https://doi.org/10.1016/j.matdes.2018.09.048
Xu XY, Ma XD, Wang H et al (2019) Characterization of residual stresses and microstructural features in an Inconel 718 forged compressor disc. Trans Nonferrous Metals Soc China 29(3):569–578. https://doi.org/10.1016/S1003-6326(19)64965-4
Choda T, Oyama H, Murakami S (2015) Technologies for process design of titanium alloy forging for aircraft parts. KOBELCO Technol Rev 33:44–49
Kim PH, Chun MS, Yi JJ, Moon YH (2002) Pass schedule algorithms for hot open die forging. J Mater Process Technol 130:516–523. https://doi.org/10.1016/S0924-0136(02)00798-7
Hibbe P, Hirt G (2020) Analysis of the bond strength of voids closed by open-die forging. Int J Mater Form 13(1):117–126. https://doi.org/10.1007/s12289-019-01474-7
Choi SK, Chun MS, Van Tyne CJ et al (2006) Optimization of open die forging of round shapes using FEM analysis. J Mater Process Technol 172(1):88–95. https://doi.org/10.1016/j.jmatprotec.2005.09.010
Chun MS, Van Tyne CJ, Moon YH (2006) FEM analysis of void closure behavior during open die forging of rectangular billets. Steel Res Int 77(2):116–121. https://doi.org/10.1002/srin.200606363
Lee YS, Lee SU, Van Tyne CJ et al (2011) Internal void closure during the forging of large cast ingots using a simulation approach. J Mater Process Technol 211(6):1136–1145. https://doi.org/10.1016/j.jmatprotec.2011.01.017
Marini D, Corney JR (2020) Process selection methodology for near net shape manufacturing. Int J Adv Manuf Technol 106(5-6):1967–1987. https://doi.org/10.1007/s00170-019-04561-w
Zhang Y, Shan D, Xu F (2009) Flow lines control of disk structure with complex shape in isothermal precision forging. J Mater Process Technol 209(2):745–753. https://doi.org/10.1016/j.jmatprotec.2008.02.058
Prasad K, Sarkar R, Ghosal P, Kumar V (2010) Tensile deformation behaviour of forged disc of IN 718 superalloy at 650 C. Mater Des 31(9):4502–4507. https://doi.org/10.1016/j.matdes.2010.04.019
Behrens B, Stonis M, Rasche N (2018) Influence of the forming angle in cross wedge rolling on the multi-directional forging of crankshafts. Int J Mater Form 11(1):31–41. https://doi.org/10.1007/s12289-016-1326-3
Gey N, Bocher P, Uta E, Germain L, Humbert M (2012) Texture and microtexture variations in a near-a titanium forged disk of bimodal microstructure. Acta Mater 60(6-7):2647–2655. https://doi.org/10.1016/j.actamat.2012.01.031
Park KS, Van Tyne CJ, Moon YH (2007) Process analysis of multistage forging by using finite element method. J Mater Process Technol 187:586–590. https://doi.org/10.1016/j.jmatprotec.2006.11.036
Zhao DW, Jin WZ, Lei WANG et al (2006) Inner-product of strain rate vector through direction cosine in coordinates for disk forging. Trans Nonferrous Metals Soc China 16(6):1320–1324. https://doi.org/10.1016/S1003-6326(07)60013-2
Moon YH, Kim DW, Van Tyne CJ (2008) Analytical model for prediction of sidewall curl during stretch-bend sheet metal forming. Int J Mech Sci 50(4):666–675. https://doi.org/10.1016/j.ijmecsci.2008.01.003
Alexandrov S, Lyamina E, Jeng YR (2017) A general kinematically admissible velocity field for axisymmetric forging and its application to hollow disk forging. Int J Adv Manuf Technol 88(9-12):3113–3122. https://doi.org/10.1007/s00170-016-9018-1
Nowak J, Madej L, Grosman F, Pietrzyk M (2010) Material flow analysis in the incremetal forging technology. Int J Mater Form 3(S1):931–934. https://doi.org/10.1007/s12289-010-0921-y
Montazeri-Pour M, Parsa MH, Jafarian HR, Taieban S (2015) Microstructural and mechanical properties of AA1100 aluminum processed by multi-axial incremental forging and shearing. Mater Sci Eng A 639(15):705–716. https://doi.org/10.1016/j.msea.2015.05.066
Deng X, Hua L, Han X, Song Y (2011) Numerical and experimental investigation of cold incremental forging of a 20CrMnTi alloy spur bevel gear. Mater Des 32(3):1376–1389. https://doi.org/10.1016/j.matdes.2010.09.015
Wernicke S, Hahn M, Gerstein G, Nürnberger F, Tekkaya AE (2020) Strain path dependency in incremental sheet-bulk metal forming. Int J Mater Form. https://doi.org/10.1007/s12289-020-01537-0
Gordon WA, Van Tyne CJ, Moon YH (2007) Axisymmetric extrusion through adaptable dies-part 1: flexible velocity fields and power terms. Int J Mech Sci 49(1):86–95. https://doi.org/10.1016/j.ijmecsci.2006.07.011
Gordon WA, Van Tyne CJ, Moon YH (2007) Axisymmetric extrusion through adaptable dies-part 3: minimum pressure streamlined die shapes. Int J Mech Sci 49(1):104–115. https://doi.org/10.1016/j.ijmecsci.2006.07.013
Chand S, Chandrasekhar P, Singh S (2018) Analysis of dynamic effects during rotary forging of cylindrical sintered preforms. Mater Today: Proc 5(9):19313–19320. https://doi.org/10.1016/j.matpr.2018.06.290
Jang JH, Lee JH, Joo BD et al (2009) Flow characteristics of aluminum coated boron steel in hot press forming. Trans Nonferrous Metals Soc China 19(4):913–916. https://doi.org/10.1016/S1003-6326(08)60376-3
Kim ES, Lee KH, Moon YH (2000) A feasibility study of the partial squeeze and vacuum die casting process. J Mater Process Technol 105(1-2):42–48. https://doi.org/10.1016/S0924-0136(00)00557-4
Jung HK, Kang CG, Moon YH (2000) Induction heating of semisolid billet and control of globular microstructure to prevent coarsening phenomena. J Mater Eng Perform 9(1):12–23. https://doi.org/10.1361/105994900770346222
Chen K, Yang Y, Shao G, Liu K (2012) Strain function analysis method for void closure in the forging process of the large-sized steel ingot. Comput Mater Sci 51(1):72–77. https://doi.org/10.1016/j.commatsci.2011.07.011
Hwang TW, Woo YY, Han SW, Moon YH (2018) Functionally graded properties in directed-energy-deposition titanium parts. Opt Laser Technol 105:80–88. https://doi.org/10.1016/j.optlastec.2018.02.057
Kim DK, Woo YY, Park KS, Sim WJ, Moon YH (2018) Advanced induction heating system for hot stamping. Int J Adv Manuf Technol 99(1–4):583–593. https://doi.org/10.1007/s00170-018-2385-z
Banaszek G, Stefanik A (2006) Theoretical and laboratory modelling of the closure of metallurgical defects during forming of a forging. J Mater Process Technol 177(1–3):238–242. https://doi.org/10.1016/j.jmatprotec.2006.04.023
Banaszek G, Berski S, Dyja H, Kawałek A (2013) Theoretical modelling of metallurgical defect closing-up processes during forming a forging. J Iron Steel Res Int 20(9):111–116. https://doi.org/10.1016/S1006-706X(13)60165-X
Zhang ZJ, Dai GZ, Wu SN, Dong LX, Liu LL (2009) Simulation of 42CrMo steel billet upsetting and its defects analyses during forming process based on the software DEFORM-3D. Mater Sci Eng A 499(1–2):49–52. https://doi.org/10.1016/j.msea.2007.11.135
Dyja H, Banaszek G, Berski S, Mróz S (2004) Effect of symmetrical and asymmetrical forging processes on the quality of forged products. J Mater Process Technol 157:496–501. https://doi.org/10.1016/j.jmatprotec.2004.07.109
Lin SY (1999) Upsetting of a cylindrical specimen between elastic tools. J Mater Process Technol 86(1-3):73–80. https://doi.org/10.1016/S0924-0136(98)00236-2
Bagherpour E, Pardis N, Reihanian M, Ebrahimi R (2019) An overview on severe plastic deformation: research status, techniques classification, microstructure evolution, and applications. Int J Adv Manuf Technol 100(5-8):1647–1694. https://doi.org/10.1007/s00170-018-2652-z
Jafarpour AM, Asl AS, Bihamta R (2010) Simulation and studying of conical gears forging. Trends Appl Sci Res 5(1):16–28. https://doi.org/10.3923/tasr.2010.16.28
Ivaniski TM, Epp J, Zoch H et al (2019) Austenitic grain size prediction in hot forging of a 20MnCr5 steel by numerical simulation using the JMAK model for industrial applications. Mater Res 22(5):e20190230. https://doi.org/10.1590/1980-5373-mr-2019-0230
Acknowledgments
This work was supported by the National Research Foundation of Korea (NRF) grant funded by the Korea government(MSIT) (No.2019R1A5A6099595).
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that they have no known competing financial interests.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Kim, N., Oh, I.Y., Han, S.W. et al. Advanced disk-forging process in producing heavy defect-free disk using counteracting dies. Int J Mater Form 14, 281–291 (2021). https://doi.org/10.1007/s12289-020-01595-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12289-020-01595-4