Details
| Original language | English |
|---|---|
| Pages (from-to) | 140-145 |
| Number of pages | 6 |
| Journal | Materials and Manufacturing Processes |
| Volume | 29 |
| Issue number | 2 |
| Publication status | Published - 4 Mar 2014 |
| Externally published | Yes |
Abstract
Recent research dealt with the basic forgeability of aluminum-matrix composites produced under laboratory conditions. These research projects concentrated on metallurgy and, by deriving flow curves, on formability. In contrast to laboratory conditions, the industrial use requires large batches of raw materials and takes place under real conditions. Those conditions have not yet been analyzed. This paper describes the combination of mechanical advantages of aluminum-matrix composites and a flashless forging process. The advantages can be outlined as higher part strength, compared to conventional forging parts with the same weight. Newly derived flow curves demonstrate formability and were used to evaluate basic forging parameters. The first forging trials in a conventional forging process using a high forging rate resulted in broken parts and therefore required a reduced deformation rate. The matrix slug material provides a higher deformation rate but has to be reduced, due to the use of metal-matrix composites (MMCs). Using a conventional forging press (e.g., screw press) causes material failures likes cracks, because forging Al-MMCs requires a reduced forming speed of 20 mm/s. Reducing the forming speed, hydraulic presses are recommended. Finite Element (FE) analysis of the newly developed flashless forging process is described and depicts the basic forming operations (spreading, elongating and climbing) of the material in the forging die. Altogether a new strategy for a flashless forging process layout with Al-MMC is shown.
Keywords
- Aluminum, Characterization, Composite, FEA, Flashless, Forging, Matrix, Simulation, Tool, Upsetting
ASJC Scopus subject areas
- Materials Science(all)
- General Materials Science
- Engineering(all)
- Mechanics of Materials
- Engineering(all)
- Mechanical Engineering
- Engineering(all)
- Industrial and Manufacturing Engineering
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In: Materials and Manufacturing Processes, Vol. 29, No. 2, 04.03.2014, p. 140-145.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Analysis of Material Characteristics and Forging Parameters for Flashless Forged Aluminum-Matrix Composites
AU - Stonis, Malte
AU - Rüther, Tilmann
AU - Behrens, Bernd Arno
N1 - Funding information: FUNDING T he authors thank the German Research Foundation (DFG) for the financial funding for the accomplishment of the research project.
PY - 2014/3/4
Y1 - 2014/3/4
N2 - Recent research dealt with the basic forgeability of aluminum-matrix composites produced under laboratory conditions. These research projects concentrated on metallurgy and, by deriving flow curves, on formability. In contrast to laboratory conditions, the industrial use requires large batches of raw materials and takes place under real conditions. Those conditions have not yet been analyzed. This paper describes the combination of mechanical advantages of aluminum-matrix composites and a flashless forging process. The advantages can be outlined as higher part strength, compared to conventional forging parts with the same weight. Newly derived flow curves demonstrate formability and were used to evaluate basic forging parameters. The first forging trials in a conventional forging process using a high forging rate resulted in broken parts and therefore required a reduced deformation rate. The matrix slug material provides a higher deformation rate but has to be reduced, due to the use of metal-matrix composites (MMCs). Using a conventional forging press (e.g., screw press) causes material failures likes cracks, because forging Al-MMCs requires a reduced forming speed of 20 mm/s. Reducing the forming speed, hydraulic presses are recommended. Finite Element (FE) analysis of the newly developed flashless forging process is described and depicts the basic forming operations (spreading, elongating and climbing) of the material in the forging die. Altogether a new strategy for a flashless forging process layout with Al-MMC is shown.
AB - Recent research dealt with the basic forgeability of aluminum-matrix composites produced under laboratory conditions. These research projects concentrated on metallurgy and, by deriving flow curves, on formability. In contrast to laboratory conditions, the industrial use requires large batches of raw materials and takes place under real conditions. Those conditions have not yet been analyzed. This paper describes the combination of mechanical advantages of aluminum-matrix composites and a flashless forging process. The advantages can be outlined as higher part strength, compared to conventional forging parts with the same weight. Newly derived flow curves demonstrate formability and were used to evaluate basic forging parameters. The first forging trials in a conventional forging process using a high forging rate resulted in broken parts and therefore required a reduced deformation rate. The matrix slug material provides a higher deformation rate but has to be reduced, due to the use of metal-matrix composites (MMCs). Using a conventional forging press (e.g., screw press) causes material failures likes cracks, because forging Al-MMCs requires a reduced forming speed of 20 mm/s. Reducing the forming speed, hydraulic presses are recommended. Finite Element (FE) analysis of the newly developed flashless forging process is described and depicts the basic forming operations (spreading, elongating and climbing) of the material in the forging die. Altogether a new strategy for a flashless forging process layout with Al-MMC is shown.
KW - Aluminum
KW - Characterization
KW - Composite
KW - FEA
KW - Flashless
KW - Forging
KW - Matrix
KW - Simulation
KW - Tool
KW - Upsetting
UR - http://www.scopus.com/inward/record.url?scp=84896764938&partnerID=8YFLogxK
U2 - 10.1080/10426914.2013.822986
DO - 10.1080/10426914.2013.822986
M3 - Article
AN - SCOPUS:84896764938
VL - 29
SP - 140
EP - 145
JO - Materials and Manufacturing Processes
JF - Materials and Manufacturing Processes
SN - 1042-6914
IS - 2
ER -