Influence of Process Parameters on Electric Upsetting Process by Using Finite Element Modeling

Electric Upsetting Process (EUP) is a process combining the forming process with the electric heating system. It is commonly used to manufacture a preform of a bar with high upsetting ratio, such as an axial shaft. The reliable forming process requires the understanding the effect of process and electrical parameters. Currently, the designer develops this process by trail-and-error. To successfully develop this process, the relationship between the electric heating and the forming parameters needs to be clearly understood. In this study, three parameters are investigated; namely anvil speed, upsetting load and heating voltage. Finite Element Modeling (FEM) is used as a tool for evaluating these parameters. The FEM results indicate that those parameters play significant roles on the material flow as well as the heating characteristics (i.e. temperature distributions and heat flow).

Microstructure and Properties Characterization of Polycrystalline Ni-Fe-Cr-Based Superalloy EP-718E after Electric Upsetting

The purpose of this study is to analyze the effect of electric upsetting on the microstructure defects eliminating and mechanical properties evolution of the Ni-Fe-Cr-based polycrystalline superalloy EP718E. The microstructure was examined by scanning electron microscope and energy dispersive spectrometry techniques. The material mechanical properties were characterized by nanoindentation, by tension testing of micro samples and high cycle fatigue testing at room temperature. The results show, that the microstructure defects on confluence of grain boundaries (depending on the processing stages) were step-by-step eliminated. The tension stress was lowered but elongation was increase. As a result of such changes in microstructure and mechanical properties of alloy the fatigue strength (δ-1) was increased from δ-1 = 300 MPa to δ-1 = 540 MPa and the number of cycles to failure was increased from N1 = 2·107 up to N4 = 4 x (2·107), respectively.

Simulation of Electric Upsetting and Forging Process for Large Marine Diesel Engine Exhaust Valves

The manufacturing process of the exhaust valve in large marine diesel engines consists of an upset forging and final forming process. In the past, the exhaust valves in large marine diesel engines have been made through free forging by using the stretch forming method. This method has used the ingot and the billet as a preliminary forming process. Nimonic 80A, a superalloy, is presently used for the material of the exhaust valve. For the forming method of the valve, the electric upset method is used. Solid bar is raised up to the forming temperature by using electric energy and is continually deformed by upset pressure. The electric upsetting processing is a useful method for the high quality of exhaust valves in large marine diesel engines. It can keep the continuous grain flow, excellent mechanical property, and corrosion resistance because of the elaborate macrostructure of the valve face. The purpose of this paper is to predict the optimum process condition through simulation of the exhaust valve with a diameter of 73mm. The experimental result of an exhaust valve with a diameter of 19mm is in good agreement with the simulation result using the “QForm” that can solve electric upsetting problems. Finally, the optimal manufacturing process of the electric current and the upset load are surveyed.