TY - JOUR

T1 - Simulation algorithm for the assessment and modification of multi-directional forging processes and tool geometries

AU - Behrens, B. A.

AU - Nickel, R.

AU - Stonis, M.

N1 - Funding information: Acknowledgments The authors thank the German Research Foundation (Deutsche Forschungsgemeinschaft) for the funding of the research project ‘‘Aluminiumschmieden von Langteilen mit genauer Massevorverteilung’’ (DFG Do 190/167-1 and DFG Be 1691/19-2).

PY - 2012/2/15

Y1 - 2012/2/15

N2 - In automotive industry, parts made of aluminum alloys are used with increasing frequency. During forging operations for the production of aluminum long flat pieces, defects like folds can appear. Especially internal folds are of interest, which are only evident in the fiber orientation and have a negative effect on the dynamic mechanical properties of the forged part. In forging, the forming operation can be realized either from one direction (uni-directional) or from several directions (multi-directional). The boundary conditions for multi-directional forging are described in this article. For a given tool geometry, multi-directional forging permits the realization of fold-free forgings, which has been shown to be not possible with uni-directional operations. A newly developed method based on finite-elements-analysis simulation helps with the design of the forming process and the determination of the appropriate tool geometry. A new algorithm integrates the computer-aided identification of internal folds. For a given process and tool geometry, the area with internal folds is adjusted, until the simulation shows no fold formation. It is shown, that by using this model, a dependable assessment and correction of forging tools and forming process and thus the realization of a fold-free forming are possible.

AB - In automotive industry, parts made of aluminum alloys are used with increasing frequency. During forging operations for the production of aluminum long flat pieces, defects like folds can appear. Especially internal folds are of interest, which are only evident in the fiber orientation and have a negative effect on the dynamic mechanical properties of the forged part. In forging, the forming operation can be realized either from one direction (uni-directional) or from several directions (multi-directional). The boundary conditions for multi-directional forging are described in this article. For a given tool geometry, multi-directional forging permits the realization of fold-free forgings, which has been shown to be not possible with uni-directional operations. A newly developed method based on finite-elements-analysis simulation helps with the design of the forming process and the determination of the appropriate tool geometry. A new algorithm integrates the computer-aided identification of internal folds. For a given process and tool geometry, the area with internal folds is adjusted, until the simulation shows no fold formation. It is shown, that by using this model, a dependable assessment and correction of forging tools and forming process and thus the realization of a fold-free forming are possible.

KW - Algorithm

KW - Aluminum forging

KW - Finite-elements-analysis

KW - Internal folds

KW - Multi-directional forging

KW - Tool geometry

UR - http://www.scopus.com/inward/record.url?scp=84859162312&partnerID=8YFLogxK

U2 - 10.1007/s11740-012-0364-z

DO - 10.1007/s11740-012-0364-z

M3 - Article

AN - SCOPUS:84859162312

VL - 6

SP - 187

EP - 198

JO - Production Engineering

JF - Production Engineering

SN - 0944-6524

IS - 2

ER -