This diploma thesis has been elaborated within the Master's study of department 2307 that submits a production proposal of supporting holder by solid forming. The used material of the forging is steel ČSN 12050 with yearly production of 100 000 pieces. The forging has been performed using drop forging method by two operations at the crank forging press LZK 1000, with induction heating of semi-finished product and flash trimming at the trimming press LKOA 200. For this method have been performed required technological calculations, geometric design of the die and assigning production machines needed for this technology. A part of this study is an economical evaluation where have been stated production expenses and prices of the forging of assigned component.

The project elaborated in frame of the engineering studies branch N2326 presenting the design of manufacturing technology of forging carrier of steel 14 220. Pursuant to the literary pursuit a problem of solid hot forming was proposed to product by drop forging with flash on 3 forging operations. All the operations are realized on the vertical crank forging press LZK 4000 B produced by ŠMERAL BRNO a.s. with nominal forming force 40 NM. Heating material on the forging temperature 1100 °C will proceed in the electric induction furnace produced by ROBOTERM s.r.o. type KSO 800kW, the flash trimming on the trimming press LDO 315 A/S with nominal forming force 3,15 MN. Dies are made from tool steel 19 552.9 and strapped in die holder QLZK 4000/UC. A part of the project is technical economic analysis evaluation and elaboration of production scheme. Expected annual volume is 100 000 pieces.

This diploma thesis has been elaborated within the Master's study that submits a production proposal of carrying body by solid forming. The forging has been performed using drop orging method at the crank forging press LZK 1000. Heating is inductive and flash trimming has been peformed in the trimming press LKOA 200. The used material of the forging is steel CSN 14 220. Production series is 100 000 pieces. A part of this thesis is calkulations, geometric design and economical evaluation.

This diploma thesis, which has been elaborated within Master's study programme Manufacturing Technology and Management in Industry (2303T005), submits a production proposal of production of bottom body by solid forming and its economical evaluation containing all the economical essentials needed in order to produce and specify the final price of a forging. This thesis takes in all the necessary calculations and machinery proposals according to the material of dies and to annual capacity of 250 000 pieces of forgings requested. Semi-finished product for the manufacture of forging is cut size of bars of circular cross-section of steel 14 220 ČSN 42 5510.

The diploma thesis deals with problems of drop forging. A detailed literary study is prepared in this work, in which there are data for working out the specified component – mudguard holder. There are options for cutting the semi-product, types of lubricants, construction of ideal preform or different kinds of forging machines for drop forging. The next part of this thesis is about technology of drop forging on crank forging presses. This section is aimed on technical drawing of the forging and its classification by the complexity of the shape. Furthermore, the thesis deals with the economic part, setting out the individual costs of the production from which the cost price of a forging is determined.

O presente trabalho, apresenta resultados da investigação experimental e da análise computacional acerca do método de ensaio de anéis de aço para obtenção do valor do coeficiente de atrito, existente na região de contato entre as matrizes e os corpos de prova. Buscando atingir os objetivos, foi feito um planejamento do experimento, através do programa MINITAB (2000), levando-se em consideração as variáveis do processo para forjamento a quente de peças para indústria automotiva, os experimentos foram realizados nos laboratórios da Universidade Federal do Rio Grande do Sul (UFRGS). A simulação do ensaio de anel permitiu uma boa estimativa da redução de diâmetros dos mesmos, bem como, do fluxo de material no interior dos anéis e da superfície neutra. A análise estatística dos resultados mostrou que a variável mais importante a afetar o coeficiente de atrito foi a temperatura, seguindo-se do tipo de revestimento das ferramentas, velocidade e material. Para um estudo mais pormenorizado do efeito do material a ser forjado, do recobrimento das ferramentas e da rugosidade das mesmas no coeficiente de atrito será necessário um maior número de repetições dos experimentos. / The present work introduces the result of the experimental investigation and computing analyses regarding the method of trial with steel rings as to obtain the value of friction coefficient, which exist in the contact area between the tools and test bodies. Aiming to reach the objectives, a design of experiments was established through the program MINITAB (2000) taking into account the process variables in order to hot forge parts for the automotive industry, being such experiments accomplished at the laboratories of the Universidade do Rio Grande do Sul (UFRGS). The simulation trial of the ring allowed for good estimate of its diameters reduction as well as internal material flow in the rings and in the neutral surface. The static analyses of the results demonstrated that the most important isolated variable to affect the friction coefficient was temperature, followed by the type of tools covering, velocity and material. However a bigger number of experiments repetitions will be necessary in order to reach a more detailed study about the effect of the material to be forged, of tools covering and roughness in the friction coefficient as well.

Sheet metal surfaces with pin-fin features have potential fluid and thermal applications. Extrusion forging process and extrusion rolling process can be used to create such surface features on sheet metals. Extrusion forging process is a metal forming process that combines extrusion and forging into one operation. In extrusion forging, the pin-fin surface feature is created by compressing the work-piece using a punch with designed cavities. Experiments and numerical analysis were conducted to investigate the effects of tooling geometries, material properties, work-piece thickness, thickness reduction ratio and friction on the deformation behavior of sheet metals. It was found that increasing fillet radius of the orifice results in decrease in compressive force and boss height. As the negative draft angle increases, the compressive force and boss height decrease. Higher yield strength and higher friction lead to higher compressive force. The boss height is not significantly affected by the friction between the tooling and the work-piece. Due to limitation in force capacity, it may not be feasible to apply extrusion forging technique to generate surface features on large surface area. As such, the extrusion rolling process is proposed. In extrusion rolling, the pin-fin feature is created by compressing the strip using a pair of rolls. The upper roll is manufactured with surface cavities. Finite element method are employed to investigate the effects of rolling speed, thickness reduction ratio, roll diameter and front tension force on the deformation behavior of metal strip. It was found that the rolling speed has little influence on the roll force and boss height. The front tension force has little effect on the average pressure and boss height. Increase the roll diameter results in in roll force increase. This research investigated the effect of parameters on the deformation behavior during the extrusion forging and extrusion rolling processes. The research generated the knowledge needed for design and manufacture of micro/meso surface features on thin metal sheet. Moreover, this thesis presents a novel bulk forming process on metal sheets, which can have significant impacts in industrial practice.

Thesis (Ph. D.)--Ohio University, June, 1999. / Title from PDF t.p.

Thesis (M.S.)--Ohio University, August, 1996. / Title from PDF t.p.

Thesis (Ed.D.)--Teachers College, Columbia University, 1972. / Typescript; issued also on microfilm. Sponsor: Douglas R. McManis. Dissertation Committee: Harvey A. Levenstein. Includes bibliographical references.