scholarly journals Forging of Mg-Al-Zn Magnesium Alloys on Screw Press and Forging Hammer

Materials ◽  
2020 ◽  
Vol 14 (1) ◽  
pp. 32
Author(s):  
Andrzej Gontarz ◽  
Krzysztof Drozdowski ◽  
Jacek Michalczyk ◽  
Sylwia Wiewiórowska ◽  
Zbigniew Pater ◽  
...  
Keyword(s):  
Magnesium Alloys ◽  
High Speed ◽  
Experimental Tests ◽  
Screw Press ◽  
Forging Process ◽  
Die Forging ◽  
Upset Forging ◽  
High Speed Forming ◽  
Ram Speed ◽  
Forming Tools

Magnesium alloys are highly strain rate sensitive and exhibit good workability in a narrow forging temperature range. Consequently, parts made of these materials are usually forged with low-speed hydraulic presses, using specially designed tool heating systems in order to ensure near-isothermal conditions. This study investigates whether popular magnesium alloys such as Mg-Al-Zn can be forged in forging machines equipped with high-speed forming tools. Experimental upset forging tests on AZ31B, AZ61A and AZ80A specimens were conducted, using a screw press with a ram speed of 0.5 m/s and a die forging hammer with a ram speed at stroke of about 5 m/s. Test specimens were preheated to 350 °C, 410 °C and 450 °C. After the upset forging process, they were air- or water-cooled and then examined for their workability, hardness and grain size. To validate the results, a forging process for a producing handle was designed and modelled by the finite element method. Distributions of strain, temperature and fracture criterion were analysed, and energy and force parameters of the forging process were calculated. After that, experimental tests were performed on AZ31B and AZ61A specimens in order to determine mechanical properties of forged parts and examine their micro- and macrostructure. Results have demonstrated that AZ80A is not suitable for forging with either the screw press or the die forging hammer, that AZ61A can be press- and hammer-forged but to a limited extent, and that AZ31B can be subjected to forging in both forging machines analysed in the study.

A study of a new screw press forging process for producing aircraft drop forgings made of magnesium alloy AZ61A

2018 ◽  
Vol 90 (3) ◽  
pp. 559-565 ◽  
Author(s):  
Andrzej Gontarz ◽  
Krzysztof Drozdowski ◽  
Anna Dziubinska ◽  
Grzegorz Winiarski
Keyword(s):  
Magnesium Alloy ◽  
Production Efficiency ◽  
Ferrous Metal ◽  
Screw Press ◽  
Manufacturing Costs ◽  
Content Type ◽  
Fundamental Parameters ◽  
Forging Process ◽  
Die Forging

Purpose The aim of this study is to develop a die forging process for producing aircraft components made of magnesium alloy AZ61A using a screw press. Design/methodology/approach The proposed forging technique has been developed based on the results of a numerical and experimental research. The required forging temperature has been determined by upsetting cylindrical specimens on a screw press to examine both plasticity of the alloy and the quality of its microstructure. The next stage involved performing numerical simulations of the designed forging processes for producing forgings of a door handle and a bracket, both made of magnesium alloy AZ61A. The finite element method based on simulation programme, Deform 3D has been used for numerical modelling. The numerical results revealed that the forgings are free from material overheating and shape defects. In addition to this, the results have also helped determine the regions that are the most prone to cracking. The final stage of the research involved performing forging tests on a screw press under industrial conditions. The forgings of door handles and brackets were made, and then these were tested for their mechanical and structural properties. The results served as a basis for assessing both the viability of the designed technique and the quality of the produced parts. Findings The experimental results demonstrate that aircraft components made of magnesium alloy AZ61A can be produced by die forging on screw presses. The results have been used to determine the fundamental parameters of the process such as the optimum forging temperature, the method of tool heating, the way of cooling parts after the forging process, and the method of thermal treatment. The results of the mechanical and structural tests confirm that the products meet the required quality standards. Practical implications The developed forging technique for alloy AZ61A has been implemented by the forging plant ZOP Co. Ltd in Swidnik (Poland), which specializes in the manufacturing of aircraft components made of non-ferrous metal alloys. Originality/value Currently, the global tendency is to forge magnesium alloys (including alloy AZ61A) on free hydraulic presses using expensive die-heating systems. For this reason, the production efficiency of such forging processes is low, while the manufacturing costs are high. The proposed forging technique for alloy AZ61A is an innovative method for producing forgings using relatively fast and efficient machines (screw presses). The proposed forging method can be implemented by forging plants equipped with standard stocks of tools, which increases the range of potential manufacturers of magnesium alloy products. In addition, this technology is highly efficient and ensures reduced manufacturing costs.

Potentials of Pulse Magnetic Forming and Joining

2014 ◽  
Vol 907 ◽  
pp. 349-364 ◽  
Author(s):  
Eckart Uhlmann ◽  
Lukas Prasol ◽  
Alexander Ziefle
Keyword(s):  
Magnesium Alloys ◽  
Metal Forming ◽  
High Speed ◽  
Weld Zone ◽  
Basic Research ◽  
Magnetic Pulse ◽  
Magnetic Pulse Welding ◽  
High Speed Forming ◽  
Pulse Welding ◽  
Welding Processes

Magnetic pulse production methods such as forming, joining or separating demonstrate innovative high-speed processes. Such processes can be realized using a capacitor and an appropriate tool coil for forming and welding processes. The process strain rates, which can amount to 20,000 s-1, increase the formability of metallic materials significantly. Magnesium and aluminium alloys find a wider application in the automotive industry due to their light weight potential. Through the low density of these materials, the vehicle weight can be reduced considerably. Due to the hexagonal lattice of magnesium alloys industry-relevant deformation in metal forming processes can only be achieved in hot forming processes. The high-speed forming allows a significant increase of deformability of this alloy. The use of dissimilar metals in an assembly requires the development of innovative joining methods. Apart from being used form and force closure the magnetic pulse welding and adhesive bonding material with different partners is possible. Currently at the Institute for Machine Tools and Factory Management (IWF), TU Berlin, various research topics in the field of pulsed magnetic are investigated. The magnetic pulse sheet metal forming of magnesium alloys at room temperature is investigated in a basic research project. A defined demarcation of high-speed forming with respect to the quasi-static deformation is done by means of hardness measurements in the deformation zone. For this purpose a suitable experimental setup with different matrices is constructed. The experimental results of the pulse magnetic deformation are iteratively compared with simulation results. The aim is to develop a new material model which gives a precise prediction about the high-speed process. In the field of magnetic pulse welding, both basic research and industry-related research projects conducted at the IWF. The process requires an adapted tool coil geometry that meets the requirements of the weld geometry. Different coil geometries and weld geometries and possible applications are presented by way of example, the welding quality is quantified by means of different analytical methods. The material microstructure in the weld zone, characterized by light and scanning electron microscopy shows the typical features of a shock welded joint, as also observed in explosive welding.

Die Forging of High-Strength Magnesium Alloys – the Structure and Mechanical Properties in Different Heat Treatment Conditions / Kucie Matrycowe Wysokowytrzymałych Stopów Mg – Struktura I Własciwosci Mechaniczne W Róznych Stanach Obróbki Cieplnej

2013 ◽  
Vol 58 (1) ◽  
pp. 127-132 ◽  
Author(s):  
B. Płonka ◽  
M. Lech-Grega ◽  
K. Remsak ◽  
P. Korczak ◽  
A. Kłyszewski
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Magnesium Alloys ◽  
High Strength ◽  
Hydraulic Press ◽  
Forging Process ◽  
Fine Grained ◽  
Die Forging ◽  
Treatment Conditions ◽  
Fine Grained Structure

The object of this study was to develop parameter of the die forging process, such as feedstock temperature and to investigate her impact on the structure and mechanical properties of magnesium alloys in different heat treatment conditions. Tests were carried out on a 2,5MN maximum capacity vertical hydraulic press using forgings of sample (model) shapes. Then, based on the results obtained in previous work, research was carried out to develop for items forged from magnesium alloys the parameters of heat treatment to the T5 and T6 condition in the context of achieving possibly homogeneous and fine-grained structure and, consequently, high mechanical properties.

An investigation into the effect of variable flash thickness on the strength of an AA7075 part obtained by hot closed-die forging

2014 ◽  
Vol 229 (5) ◽  
pp. 916-925 ◽  
Author(s):  
Saeed Zare Chavoshi ◽  
Mehdi Tajdari ◽  
Xichun Luo
Keyword(s):  
Flow Distribution ◽  
Experimental Tests ◽  
Tensile Tests ◽  
Optical Microscope ◽  
Operational Conditions ◽  
Forging Process ◽  
Die Forging ◽  
Closed Die Forging ◽  
Grain Flow ◽  
Finite Volume Simulation

Strength is an important specification for the forged part. This research investigates the macrostructure and grain flow distribution of material during the hot closed-die forging process of an AA7075 part by using variable flash thickness dies. Experimental tests were performed using operational conditions based on the finite volume simulation results of the forging process. The grain flow pattern and the strength of the produced parts were evaluated by using optical microscope after etching and tensile tests, respectively. It shows that using a variable flash thickness die can significantly increase the tensile strength of the forged parts.

Assessment of two different constitutive models in High Speed Forming

2019 ◽  
Author(s):  
Andrey Brezolin ◽  
Tiago dos Santos ◽  
Pedro Rosa ◽  
Evandro Paese ◽  
Martin Geier ◽  
...  
Keyword(s):  
High Speed ◽  
Constitutive Models ◽  
High Speed Forming

Development of Magnesium Alloys for High Speed Trains in China

2016 ◽  
pp. 7-8
Author(s):  
Eric Nyberg ◽  
Jian Peng ◽  
Neale R. Neelameggham
Keyword(s):  
Magnesium Alloys ◽  
High Speed ◽  
High Speed Trains

Yaw Galloping of a TLWP Platform Under High Speed Currents by Analytical Methods and its Comparison With Experimental Results

2017 ◽  
Author(s):  
Francisco Lamas ◽  
Miguel A. M. Ramirez ◽  
Antonio Carlos Fernandes
Keyword(s):  
High Speed ◽  
Production Systems ◽  
Experimental Tests ◽  
Experimental Results ◽  
Analytical Methodology ◽  
New Approach ◽  
Laboratory Facilities ◽  
Polynomial Curve ◽  
Computational Fluid Dynamics Cfd ◽  
Cfd Analyses

Flow Induced Motions are always an important subject during both design and operational phases of an offshore platform life. These motions could significantly affect the performance of the platform, including its mooring and oil production systems. These kind of analyses are performed using basically two different approaches: experimental tests with reduced models and, more recently, with Computational Fluid Dynamics (CFD) dynamic analysis. The main objective of this work is to present a new approach, based on an analytical methodology using static CFD analyses to estimate the response on yaw motions of a Tension Leg Wellhead Platform on one of the several types of motions that can be classified as flow-induced motions, known as galloping. The first step is to review the equations that govern the yaw motions of an ocean platform when subjected to currents from different angles of attack. The yaw moment coefficients will be obtained using CFD steady-state analysis, on which the yaw moments will be calculated for several angles of attack, placed around the central angle where the analysis is being carried out. Having the force coefficients plotted against the angle values, we can adjust a polynomial curve around each analysis point in order to evaluate the amplitude of the yaw motion using a limit cycle approach. Other properties of the system which are flow-dependent, such as damping and added mass, will also be estimated using CFD. The last part of this work consists in comparing the analytical results with experimental results obtained at the LOC/COPPE-UFRJ laboratory facilities.

Die Forging Process Simulation of a Connecting Rod

2011 ◽  
Vol 704-705 ◽  
pp. 302-307
Author(s):  
Lei Xu ◽  
Guang Ze Dai ◽  
Xing Ming Huang ◽  
Jing Han ◽  
Jun Wen Zhao
Keyword(s):  
Reduction Rate ◽  
Temperature Fields ◽  
Stress Fields ◽  
Connecting Rod ◽  
Preheat Temperature ◽  
Forging Process ◽  
Optimum Parameters ◽  
Die Forging ◽  
High Level ◽  
Deform 3D

Numerical simulation of connecting rod die forging processing was performed by finite element method (FEM) software Deform 3D. The changes of the temperature fields, stress fields of the billet and dies, and upper setting force-stroke curve during the die forging were obtained. The simulation results show that (1) the increase of the fillet radius of dies could effectively reduce the stress concentration so that to prevent the die crack arising at high level stress; (2) the optimum parameters of die forging process are 430°C for forging temperature, 200°C for preheat temperature of dies and 80mm/s for reduction rate by comparing both fields of the stress and temperature during different forging process..

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