Details
| Original language | English |
|---|---|
| Pages (from-to) | 187-198 |
| Number of pages | 12 |
| Journal | Production Engineering |
| Volume | 6 |
| Issue number | 2 |
| Publication status | Published - 15 Feb 2012 |
| Externally published | Yes |
Abstract
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.
Keywords
- Algorithm, Aluminum forging, Finite-elements-analysis, Internal folds, Multi-directional forging, Tool geometry
ASJC Scopus subject areas
- Engineering(all)
- Mechanical Engineering
- Engineering(all)
- Industrial and Manufacturing Engineering
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In: Production Engineering, Vol. 6, No. 2, 15.02.2012, p. 187-198.
Research output: Contribution to journal › Article › Research › peer review
}
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 -