Effective Engineering Analysis for Improving Productivity

1. INDUSTRIAL FORGING
PROCESSES – EMERGING
TRENDS AND OPPORTUNITIES
Dr. N.Ravichandran
ValueSource Engineering
Services
www.valuesource.tech

2. INDUSTRY

3. GLOBAL BUSINESS
SHARE

5. Forging is the most favored process step for
manufacturing safety critical structural components.
Being a capital intensive up-stream process, yet far
away from the line-of-sight of customers’ value
proposition, hence is at the receiving-end of
dominantly buyers’ market. Incumbents must create
value created by engineered continuous
improvements to off-set the technology edge of
new entrants. The webinar shall identify potential
developments in forging process to synergize legacy
with technology, for sustained economic growth.
Forging Die Design
Process Innovations
Dynamic Materials
Modeling
Deformation Processing
Maps
Energy Saving Options
Pacing Upgradation

6. Business Transformation from Traditional
to Engineering Companies
1.Technology transfers
2. Technology Deployment
• Engineering Analysis
• Analysis Tools
• Quality Data
• Operation Data

7. Part Design
Die Design
Process Design
Material Related Workability
Opportunities

8. PART DESIGN

9. Additive Manufacturing - Opportunities
- Topology Optimized for AM
- Intermediate to AM is Forging
Mobility Sector
- Electric Vehicles
- High Speed Trains
- Aerospace sector

10. FE Analysis
Topology Optimization
Part Integration
Light weighting
Process Preference
PART DESIGN

11. PART DESIGN
Geometries at
Intermediate stages
are new
opportunities for
forging to compete

12. Die Design &
Process Design

13. DESIGN OPTIMIZATION

14. DESIGN OPTIMIZATION
(i) preform optimisation, (ii) relief hole and (ii) relief axis.

15. DEFORMATION
STRAIN
STRAIN RATE
EFFECTIVE STRAIN
von Mises Stress
STATE-OF-STRESS
WORKABILITY
STATE - OF – STRESS RELATED
WORKABILITY
INTRINSIC WORKABILITY
MATERIAL RELATED WORKABILITY
ENGINEERING
ANALYSIS
UP-SETTING
ROLLING
EXTRUSION
BLOCKING
BLOW
EDGING
BLOCKING
TRIMMING
FE Analysis
&
Simulation

16. DESIGN OPTIMIZATION
Consider shape and size of the initial billet and predict the forces
needed as well as the defect occurrences.
Extend hot forging die life by
• minimizing the damage accumulation
• developing optimal preform design.
Consider Die-elasticity, secondary yielding, spring-back and
temperature involved.
Optimum Preform shape also should consider improved
dimensional accuracy of the forged parts
Die and Process Optimization for Improved Material Yield

17. Selection of appropriate Materials constitutive Equation in
simulation

18. DESIGN OPTIMIZATION – Case
Study

19. DESIGN OPTIMIZATION – Case
Study

20. PROCESS OPTIMIZATION – Case
Study

21. PROCESS OPTIMIZATION – Case
Study

22. MATERIAL RELATED
WORKABILITY
(Huge Opportunity for Business Growth)

24. Constitutive Equation

25. Dynamic Material Modeling

26. Deformation Processing Maps

27. Deformation Processing Maps (Prasad Maps)

28. Duplex low-density Fe–Mn–Al–C
steel

29. Engineering Analysis plays a vital role in converting challenges to
opportunities.
Identifying the right tools and nurturing strong engineering teams
is key to success
Process data and analysis can significantly improve business
performance
Adapting the emerging workability characterization techniques
help in entering into strategic and advanced materials domain.
CONCLUSIONS

30. THANK YOU