Creating material flow highways in Forging Dies
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This document summarizes research into optimizing material flow in forging dies. Experiments were conducted using dies with "speed breakers" or bumps inside impressions to channelize material flow. Deeper extrusion depths were achieved compared to plain dies without locks. Groove depths were reduced to avoid folds. Differential surface finishes and localized lubrication can further control material flow. Simulation tools can optimize flow and add localized lubrication features to design the most efficient forging processes.
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The document provides information on the history, process, types of machines, and components of injection moulding. It discusses:
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Casting
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Introduction to mp prathik
This document provides information on casting processes and pattern making. It begins with an introduction and overview of casting classification and types of production systems. It then discusses specific casting processes like sand casting and rolling. Key factors for selecting a production process are outlined. The document also defines important terms in casting, describes the basic steps of making a casting, and lists common products made through casting. It discusses the casting process in detail, provides examples of components produced through casting, and notes advantages and limitations. Finally, it introduces pattern making, comparing patterns to castings, listing pattern functions and materials, and describing common pattern allowances.
Sheet Metal Testing Challenges
With a wide range of applications varying from white goods, automotive, and aerospace applications, sheet metals are often high in strength relative to their cross section area. It’s important to note that formability and ductility is also crucial, for which the common testing requirements are similar across applications. Explore the challenges in sheet metal testing.
Rapid prototyping technologies,applications &part deposition planning 2
Rapid prototyping technologies allow for the quick fabrication of scale models using 3D CAD data. The document discusses several rapid prototyping processes like stereolithography, fused deposition modeling, and selective laser sintering. It also covers part deposition planning, which determines part accuracy, surface quality, build time and cost based on factors like tessellation, slicing, and orientation. While rapid prototyping enables faster design iterations, limitations include poor surface finish and limited strength compared to final production parts.
Vacuum forming
Vacuum forming is a thermoforming process that uses vacuum pressure to mold a plastic sheet over a mold. The process involves heating a plastic sheet until soft, draping it over a mold, applying vacuum pressure to suck the sheet onto the mold, then cooling and ejecting the molded part. Key aspects of vacuum forming include part and tool design, material selection, and processing techniques like heating, vacuum application, and cooling. Common applications are food containers, baths, vehicle interiors, and more.
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This document discusses deburring processes. It defines burrs as sharp edges created during cutting and stamping operations that can cause assembly and safety issues. Deburring is the process of removing burrs, typically through filing, sanding, or newer techniques. The document outlines several common mechanical deburring processes like cutting, power brushing, bonded abrasives, mass finishing and abrasive blasting. It also discusses less common thermal deburring using heat and electro-chemical deburring which dissolves burrs using electrolysis. The goal of deburring is to prepare metal or wood surfaces for further finishing or assembly.
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OPTIMIZATION OF EXISTING GAS PIPELINES USING ADVANCED NANOCOMPOSITES
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みなさんこんにちはこれ何文字まで入るの？40文字以下不可とか本当に意味わからないけどこれ限界文字数書いてないからマジでやばい文字数いけるんじゃないの？えこ...
ここ3000字までしか入らないけどタイトルの方がたくさん文字入ると思います。
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みなさんこんにちはこれ何文字まで入るの？40文字以下不可とか本当に意味わからないけどこれ限界文字数書いてないからマジでやばい文字数いけるんじゃないの？えこ...
みなさんこんにちはこれ何文字まで入るの？40文字以下不可とか本当に意味わからないけどこれ限界文字数書いてないからマジでやばい文字数いけるんじゃないの？えこ...
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Creating material flow highways in Forging Dies
- 1. FORGING TECHNOLOGY 2017 Creating material flow highways in forging dies- Dr. Vasant Khisty www.sammy-consulting.com
- 2. • Forging is a process in which material flows in semi-solid form. • The most efficient process is where least material, with least force, least rejection and maximum die life is achieved. • One of the process output is complete filling of the die • The paper deals on optimizing the material flow in most efficient manner Introduction
- 3. • In a forging die there are different impressions, some deep some shallow • More resistance for flow is provided to fill the deeper impression and are last to fill • Certain speed breakers and highways have to be created to channelize the flow. • Flash-less forging is getting implemented in several profiles and even in crank shafts. • Many profiles still have conventional method of providing excess volume • Conventional speed breakers were about choking the flash outside the die • Paper deals in experimenting with speed breakers and highways inside the die.
- 5. The Experiment Extrusion die like a Motor cycle crank shaft Weight:2.5 Kg Equipment: 1000 Ton press Material: Carbon steel Forging Temperature: 1200 Deg. C Lubrication: changed during experiment Die temperature: Mostly 200 Deg.C Hot Raw material transportation time 1 second Hot Raw material dwell on die 1 second. Ambient temperature 20 Deg C. Die gap 1.5 mm Die steel: H13 Die design A/ Normal first operation (Blocker) plain dies without locks B/ Dies with speed breakers or bumps inside the impression. Simulation tool used
- 6. Experiment No 1 Plain die with no flash locks Lubrication water with graphite Depth of extrusion Z axis 39.8 mm
- 7. Experiment No 2 Die with speed breakers inside the impression Lubrication water with graphite Depth of extrusion Z axis 59.71 mm
- 8. Experiment No 3 Blocker out put forged in finisher die Result deep cracks Solution reduce the depth to width ratio of grooves
- 9. Experiment 4Reduced groove depth Applied lubrication in top die only Provided vent in top die Zero lubrication in bottom die Result – Die filled. 80 mm Z axis
- 10. Experiment 5Blocker to finisher Checked for cracks Result- No cracks or folds Conclusion Groove depth can be reduced To avoid fold And achieve better extrusion
- 11. Application for deep profiles Road blocks Outside the die Ripples in shallow portions Localized lubrication
- 13. Possible constrains needing evaluation Tool life Folds and laps Forging load Die sticking.
- 14. Conclusion of research • Material flow by scientific tool and process design. • Road blocks inside the impression will give direction to flow • Differential surface finishes in the die can control the flow • Differential localized lubrication can control the flow • Simulation software can be used to optimize the flow of material • Simulation software can add localized lubrication feature • Simulation tools, tool manufacturing technology, lubrication and automation need to be scientifically utilized to get the most efficient process. This research would not be possible without the simulation tools. Thanks to QForm Pic videos : Credit QForm