Orientador: Maria Helena Robert / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-06T16:34:52Z (GMT). No. of bitstreams: 1 Silva_BeethovenMaxAlvesda_M.pdf: 3678052 bytes, checksum: 2c49240a815892ad66565deba3473b59 (MD5) Previous issue date: 2007 / Resumo: Neste trabalho investiga-se a influência da microestrutura inicial e do material do molde na tixoconformação da liga A356. São produzidas e testadas em operações de tixoforjamento pastas obtidas por três distintos processos: fusão parcial controlada de estrutlJ'aS dendríticas grosseiras, fusão parcial controlada de estruturas ultra-refinadas e pastas obtidas por agitação mecânica do líquido durante solidificação. É produzido ainda um compósito A356 + Ab03 obtido por compofundição. Os tixoforjados foram submetidos à análise metalográfica para caracterização microestrutural, medindo-se a fração da fase primária e o tamanho médio de glóbulo ou roseta da fase sólida. Os resultados obtidos mostram a viabilidade da utilização de moldes não metálicos e operações de tixoconformação com produtos de bom acabamento superficial e dimensional. As forças de tixoforjamento são dependentes da condição inicial da matéria-prima, de forma que forças maiores são requeridas com o aumento do parâmetro microestrutural básico (espaçamento interdendrítico, tamanho de glóbulo e tamanho de roseta) da matéria-prima / Abstract: This research aims the influence of initial microstructure and die material on thixofonning of A356 alloy. Obtained slurries are produced and tested in thixoforging operation by three distinct processes: controlled partial melting of coarse dendritic structures, controlled partial melting of ultra-refined structures and obtained slurries by liquid mechanical stirring during solidification. It is still produced a composite A356 + AbO:i obtained by compocasting. Thixoforged samples were submitted to metalographic analysis for microstructural characterisation, measuring the primary phase fraction and globule average size or 50lid phase rosette. Obtained results showed the viability of non-metallic dies in thixoforming operations with good superficial and dimensional finishing produds. Thixoforging forces are dependent on initial condition of raw material, 50 that higher forces are required with the increasing of basic microstructural parameter Onterdentritic spacing, globule size and rosette size) of raw material / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

Orientador: Itamar Ferreira / Tese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-20T17:14:11Z (GMT). No. of bitstreams: 1 Queiroz_SymeReginaSouza_D.pdf: 5101982 bytes, checksum: 1143c4b43c52ed713ed719367ce07ead (MD5) Previous issue date: 2012 / Resumo: A tendência mundial das estradas de ferro é utilizar carga elevada por vagão no transporte de produtos e alta velocidade no setor de passageiros. Em ambas as situações, as rodas ferroviárias são muito solicitadas mecanicamente e, em função disso, as propriedades mecânicas dessas rodas devem ser rigorosamente controladas, tendo em vista que as principais causas de acidentes envolvendo trincas nas rodas, ou a retirada da roda antes do final de sua vida, estão direta ou indiretamente associadas a baixos níveis de resistência mecânica, resistência à fadiga e tenacidade à fratura. O conhecimento do comportamento mecânico das rodas ferroviárias com base nas suas propriedades mecânicas é imprescindível para o projeto de rodas ferroviárias e para o aprimoramento de seu processo de fabricação. Este trabalho tem como objetivo caracterizar e analisar a microestrutura, as propriedades mecânicas e os micromecanismos de fratura de cinco rodas ferroviárias, duas fundidas e três forjadas, a partir de corpos-de-prova usinados dos aros e discos dessas rodas. As propriedades mecânicas analisadas são as básicas (limite de escoamento, limite de resistência à tração, alongamento específico até à fratura, redução de área, dureza e energia de impacto Charpy), a resistência à fadiga e a tenacidade à fratura, de corpos-de-prova usinados das rodas ferroviárias. Além das microestruturas e das propriedades mecânicas, foram também caracterizados e analisados os micromecanismos de fratura dos corpos-de-prova dos ensaios de fadiga e impacto, por meio de microscopia eletrônica de varredura. Os resultados dos ensaios indicam, em relação aos limites de escoamento e de resistência à tração, que não houve diferenças significativas entre as rodas fundidas e forjadas analisadas. Quanto à dureza (HRC), ductilidade (alongamento específico e redução de área) e tenacidade à fratura, as rodas forjadas apresentaram valores superiores. Em relação à resistência à fadiga, uma propriedade importante no caso de rodas ferroviárias, os corpos-de-prova usinados das rodas forjadas apresentaram melhores resultados em relação às rodas fundidas. Pode-se também concluir que, tanto para as propriedades mecânicas básicas e nobres como também para os micromecanismos de fratura, os resultados obtidos são compatíveis aos encontrados na literatura especializada, validando e comprovando que a metodologia de análise pode ser utilizada para melhorar os projetos e os processos de fabricação de rodas ferroviárias de aço fundidas e forjadas / Abstract: The word wide tendency of railroads is to use high load per wagon in cargo transport and high-speed in passenger sector. In both situations, the railway wheels are very mechanically requered, and as a result, the mechanical properties of these wheels should be controlled strictly in order that the main causes of accidents involving wheels cracks, or withdrawal of the wheel before end of its life, are directly or indirectly associated with low levels of strength, fatigue resistance and fracture toughness. Knowledge of the mechanical behavior of railway wheels based on their mechanical properties is essential for the design of railway wheels and the improvement of its manufacturing process. This work aims to characterize and analyze the microstructure, mechanical properties and fracture micromechanisms of five railway wheels, two cast and three forged, from the machined specimens of the rim and web of these wheels. The analyzed mechanical properties are the basics (yield strength, tensile strength, elongation, reduction in area, hardness and Charpy impact energy) the fatigue resistance and the fracture toughness, from the specimens machined of railway wheels. In addition to the microstructures and mechanical properties were characterized and analyzed the micromechanisms of fracture of the specimens of fatigue and impact tests, using scanning electron microscopy. The test results indicate, with respect to the yield strength and tensile strength, there were no significant differences between cast and forged wheels analyzed. The hardness (HRC), ductility (elongation and reduction in area) and fracture toughness of the forged wheels showed higher values. Regarding resistance to fatigue, an important property in the case of railway wheels, the forged wheels machined specimens shown better results compared to cast wheels. One can also conclude that, for both the basic and noble mechanical properties as well as for the micromechanisms of fracture, the results are compatible with those found in the literature, validating and verifying that the method of analysis can be used to improve the castings and forgings steel railway wheels and manufacturing processes and projects / Doutorado / Materiais e Processos de Fabricação / Doutora em Engenharia Mecânica

L'optimisation de la durée de vie des disques de turbines conçus en superalliage à base de nickel, tel que l'Inconel 718 DA, constitue une vraie problématique industrielle. En effet, lors d'essais de fatigue oligocyclique à chaud sur des éprouvettes prélevées sur ces disques, il a été constaté que la durée de vie dépendait de la zone de prélèvement testée. Cette dispersion inattendue des résultats s'avère être un facteur très important d'un point de vue industriel car le dimensionnement des pièces étant conservatif, il est établi à partir des valeurs de durée de vie les plus faibles ce qui conduit à une pénalisation forte en termes de performance du point de vue de la conception. Le but de cette étude est donc d'expliciter la relation entre les paramètres de forgeage, les propriétés microstructurales et donc les durées de vie afin de proposer des pistes pour réduire la dispersion des résultats de fatigue pour optimiser ainsi le dimensionnement des structures. Dans un premier temps, l'étude de l'effet des paramètres de forgeage a été réalisée grâce au logiciel Forge2®. Cette étape a permis de mettre en évidence les paramètres de forgeage influant sur la microstructure et de définir des gammes de forgeage sur des lopins expérimentaux. Les mécanismes d'initiation et les modes d'endommagement ont été identifiés pour chaque microstructure de l'alliage. Il s'avère que, dans le cas des matériaux testés, deux mécanismes d'amorçage sont observés : un amorçage sur particule interne avec formation de « fish-eye » et un amorçage sur grain sub-surfacique. Une corrélation directe avec la microstructure et le domaine de durée de vie a pu être établie. L'effet du rapport entre la queue de distribution de taille de grains et la taille des particules a pu être mis en évidence, ainsi que la nocivité de la présence de joints Σ3 dans des gros grains. / Optimization of turbine discs in superalloy Nickel based durability is a real industrial challenge. The different regions of a wrought Inconel 718 DA superalloy turbine disk may present a wide range of behavior in fatigue life due to the variability of the microstructure. To improve the fatigue dimensioning, it is necessary to understand the relation between the forging parameters, the microstructure and the fatigue behavior. Firstly, the effect of the forging parameters on the microstructure was realized thanks to simulation calculation via Forge2® and experimental forging were realized. Secondly, fatigue tests under strain control conditions were performed at 450°C for all microstructures. Initiation mechanisms and fracture behavior are identified for each microstructure of this superalloy. Grain size and phases distributions were characterized in the specimens and related to fatigue failure initiation modes. The 3D distribution of the Titanium nitrides was also investigated using synchrotron laminography both in terms of size and spatial distribution. Fatigue crack initiation was seen to occur on large grains in stage I for the larger grain material whereas for the material with slightly smaller grains initiation from internal nitrides caused failure via so-called fish-eye cracks. A relation between the microstructure heterogeneities and the durability is established. Indeed, the initiation mechanism, which depends on the grain size distribution compare to the particles size, impacts the durability. The presence of Σ3 boundaries in large grains proves to be harmful.

Les aciers bainitiques refroidis à l'air libre sont de plus en plus utilisés à la place des aciers martensitiques trempés et revenus pour la réalisation de pièces forgées dans le secteur automobile. Ces aciers permettent la réalisation d'économies significatives de temps et d'argent lors de leur fabrication. Leur résistance mécanique élevée est obtenue grâce à une composition chimique complexe, générant une microstructure multi-échelle et multiphasée lors du refroidissement à l'air libre. Dans un souci d'amélioration continue de cet acier, il devient nécessaire de comprendre plus en profondeur les mécanismes physiques mis en jeu lors de la décomposition de l'austénite. L'objectif principal de cette thèse est de contribuer à cette compréhension en établissant des liens quantitatifs entre la composition chimique, la microstructure et les propriétés mécaniques pour cette gamme d'aciers dans des conditions représentatives du forgeage. L'influence de plusieurs éléments d'alliage sur la microstructure brute de forge, ainsi que quelques synergies entre ces éléments, a été établie grâce à l'étude de diagrammes TRC spécifiques à l'application visée. Les mécanismes de rupture dominants et les paramètres microstructuraux contrôlant la résilience ont été identifiés par l'étude des faciès de rupture, de l'endommagement dans le volume et par des caractérisations microstructurales ciblées. Les contributions respectives de chaque mécanisme classique de durcissement structural ont été déterminées de manière quantitative, sur la base de plusieurs hypothèses et de paramètres microstructuraux. Au passage, des informations précieuses sur le comportement global en traction de ces aciers ont été récoltées grâces à l'étude des mécanismes d'endommagement et de rupture en traction.Tous ces résultats ont permis l'identification des paramètres microstructuraux, comme la taille de paquet bainitique et la fraction de constituants microstructuraux secondaires, qui doivent être pris en considération lors de l'optimisation de la composition chimique. / Air-cooled bainitic steel grades are increasingly being considered as substitutes to quenched & tempered martensitic steels in the realization of automotive forged parts. They allow significant manufacturing cost and time reductions. To compete with martensitic steels, high mechanical strength is provided by a complex chemical composition, leading to a multi-scale and multi-constituent microstructure after air-cooling. In order to optimize such chemical composition, need in rationalization of the steel grade development has emerged.The main aim of this Ph.D project was to build a physically based knowledge of the steel grade by making quantitative links between chemical composition, microstructure and mechanical properties in as-forged condition.The influence of several alloying elements on the as-forged microstructure, as well as some synergies, has been established using relevant CCT diagrams.Dominant fracture mechanisms and controlling microstructural parameters in concern of impact toughness have been identified with the help of comprehensive fracture surface, cross-section observations and targeted quantitative microstructural characterization.The respective contributions to yield strength of classical strengthening mechanisms have been quantitatively determined, based on several hypothesis and the use of several microstructural parameters. At the same, precious information on tensile behaviour has also been deduced from the observation of the fractured tensile test specimens.All these results allow identifying the key microstructural parameters, such as bainitic packet size or secondary microstructural constituents content, that have to be targeted in the alloy design.

The subject of submitted diploma thesis is complete structure of procedures necessary for the designing and subsequent production of forging dies for production of semi-finished connecting rods. The initial part deals with the design of forging die. Following part is consisted of materials used for production of this type of tools. Ensuing is proposal of tooling for machining of the die following with simulation of the milling processes.

This diploma thesis is based on proposal of manufacturing technology forging of connection rod by die forging. The connection rod is made of 12 050 steel and it is part of crank mechanism in combustion engine. Production series was specified to 120 000 pcs. for year. Into technology procedure was implemented method of cross wedge rolling before die forging. The material for transverse cross wedge rolling was chosen 19 554 steel. Process of die forging was selected three operation in vertical forging press LZK 4000 with pressure force 40 MN made by company Šmeral Brno a.s. For die material was chosen 19 552 steel. And finally was carried out technical and economical evaluation of the forging production.

This diploma thesis deals with the design and realization of a detachable joint for transferring a large torque from a drive to a driven member in a vertical forging press. The first part analyzes the disadvantages of production, assembly and disassembly of the original wedge joint of eccentric shaft and gear. The design of a new detachable joint is intended to remove the disadvantages of the original joint. Verification calculations are part of the proposal. The next part deals with the production of joint elements and the modification of the connected components for the designed joint.

The work presented has the ultimate aim to increase dynamic mechanical properties by improvements in density and optimisation of microstructure of ultra high carbon PM steels by careful selection of processes, i.e. mixing, binding, alloying, heating profile and intelligent heat treatment. ThermoCalc modelling was employed to predict liquid phase amounts for two different powder grades, Astaloy 85Mo or Astaloy CrL with additive elements such as (0.4-0.6wt%)Si, (1.2-1.4wt%)C and (1-1.5wt%)Mn, in the sintering temperature range 1285-1300ºC and such powder mixes were pressed and liquid phase sintered. In high-C steels carbide networks form at the prior particle boundaries, leading to brittleness, unless the steel is heat-treated. To assist the breaking up of these continuous carbide networks, 0.4-0.6% silicon, in the form of silicon carbide, was added. The water gas shift reaction (C + H2O = CO + H2, start from ~500ºC) and Boudouard reaction (from ~500ºC complete ~930ºC) form CO gas in the early part of sintering and can lead to large porosity, which lowers mechanical properties. With the use of careful powder drying, low dew point atmospheres and optimisation of heating profiles, densities in excess of 7.70g/cm3 were attained. The brittle microstructure, containing carbide networks and free of cracks, is transformed by intelligent heat treatment to a tougher one of ferrite plus sub-micron spheroidised carbides. This gives the potential for production of components, which are both tough and suitable for sizing to improve dimensional tolerance. Yield strengths up to 410 MPa, fracture strengths up to 950 MPa and strains of up to 16 % were attained. Forging experiments were subsequently carried out for spheroidised specimens of Fe-0.85Mo+06Si+1.4C, for different strain rates of 10-3, 10-2, 10-1 and 1sec-1 and heated in argon to 700¿C, density ~7.8g/cm3 and 769 MPa yield strength were obtained. / Libyan Education Ministry Office

No description available.

The thesis deals with the problem of large-capacity manipulation of large forgings with forging manipulator. It describes current techniques, their characteristics, advantages and disadvantages. Based on the analysis of these techniques, the thesis introduces design of the connection of the hydraulic circuit for the drive of the traveling traction wheels of the forging manipulator QKK 100 by ŽĎAS a.s. focusing on simplicity, trouble-free operation, efficiency, economy, change of speed and torque, and possibility of modification according to the current load.