Forging is a metal forming process which involves non-linear deformations. Finite element and finite volume software programs are commonly used to simulate the process. In these simulations, material properties are required. However, stress-strain relations of the materials at some elevated temperatures are not available in the material libraries of the related software programs. In this study, the stress-strain curves have been obtained by applying the Cook and Larke Simple Compression Test to AISI 1045 steel at several temperatures on a forging press with a capacity of 1000 tons. The stress-strain curves have also been determined by simulating the processes in a commercial finite element software. It is observed that experimental results are consistent with the numerical ones. A modular die set has been designed and manufactured to conduct the Cook and Larke Simple Compression Test. It has been shown that the forging press with data acquisition system can be used as a material testing equipment to obtain stress-strain curves.

<p>This doctoral thesis presents a modeling method fordemonstrating the behavior of inclusions and their surroundingmatrix during plastic deformation of steels.</p><p>Inclusions are inescapable components of all steels. Moreknowledge about their behavior in processes such as rolling andforging is necessary for carrying out the forming processes ina more proper way so that the properties of the final productare improved. This work is focussed on deformation ofinclusions together with void formation at the inclusion-matrixinterface. The topic of the work is analyzed by differentFE-codes.</p><p>The relative plasticity index is considered as an importantmeasure for describing the deformability of inclusions. Theindex could be analyzed quantitatively, enabling a deeperunderstanding of the deformation mechanisms. The workingtemperature is found to be an important process parameter. Thisis very clear when the deformation of silicate inclusions in alow-carbon steel is studied during hot rolling. Here a narrowtransition temperature region exists, meaning that theinclusion behaves as non-plastic at lower temperatures and asplastic at higher. The results are in agreement withexperiments published by other authors.</p><p>Regarding void formation, the simulations have been carriedout by utilizing an interfacial debonding criterion. Thedifference in yield stress between the matrix and the inclusionis one common reason for void initiation and propagation.During large compressive deformation the evolution of voidsgoes through a sequence of shapes, from convex with two cuspsto concave with three cusps together with self-welding lines.It is concluded that the formation of voids is alwaysassociated with a large relative sliding between the inclusionand the matrix.</p><p>In order to study the local behavior of the material closeto inclusions during hot rolling a mesomechanical approach isused. Uncoupled macro- and micro- models have been developed.By means of the macro-model, the stress-strain historythroughout each sub-volume of the steel is evaluated. Thestress components or velocity fields are recorded with respectto time as history data. No consideration is taken to theexistence of inclusions. The micro-model, which includes bothinclusion and steel matrix, utilizes the stress components orthe velocity fields from the macro-model as boundaryconditions.</p><p><b>Keywords</b>: Inclusion; Steel; Plastic deformation; Void;Rolling; Forging; Finite Element; Mesomechanical approach.</p>

Friction is one of the important parameters in metal forming processes since it affects metal flow in the die, forming load, strain distribution, tool and die life, surface quality of the product etc. The range of coefficient of friction in different metal forming applications is not well known and the factors affecting variation are ambiguous. Commercially available FEA packages input the coefficient of friction as constant among the whole process which is not a realistic approach. In this study, utility of user-subroutines is integrated into MSC SuperForm v.2004 and MSC Marc v.2003 FEA packages, to apply a variable coefficient of friction depending on the contact interface conditions. Instead of using comparatively simple friction models such as Coulomb, Shear (constant) models, friction models proposed by Wanheim-Bay and Levanov were used to simulate some cold forging operations. The FEA results are compared with the experimental results available in literature for cylinder upsetting. Results show that, large variation on the coefficient of friction is possible depending on the friction model used, the part geometry and the ratio of contact normal pressure to equivalent yield stress. For the ratio of contact normal pressure to equivalent yield stress values above 4, coefficient of friction values are approximately same for both friction models.

Thesis (Ph. D.)--Ohio State University, 2008. / Title from first page of PDF file. Includes bibliographical references (p. 254-262).

L’amélioration de la durée de vie des outillages de mise en forme à chaud constitue un enjeu industriel important et encore mal maitrisé. En effet, les sollicitations induites lors de la mise en forme mettent en jeu des couplages impliquant des phénomènes thermiques, mécaniques, tribologiques et physicochimiques. Les modes de dégradation engendrés sont multiples, principalement par déformation plastique, par fatigue thermomécanique, par frottement et par oxydation. Les dégradations par frottement demeurent parmi les plus pénalisantes et les plus difficiles à appréhender et à maîtriser compte tenu de la complexité des couplages mis en jeu.Cette thèse aborde l’usure de l’acier à outil X40CrMoV5-1 dans le cas du matriçage à chaud du laiton. Les mécanismes d’endommagement et d’usure ont été analysés par le biais d’une expertise de matrices usées en production. Elle révèle différents types de dégradations, activés selon la localisation et l’exposition des surfaces aux sollicitations cycliques de matriçage. Elle a permis d’établir un scénario d’usure par abrasion à trois corps entretenu par le cyclage et dans lequel les oxydes du laiton et de l’acier à outil sont déterminants.L’oxydation de l’acier à outil et son comportement tribologique dans un état pré-oxydé ont été étudiés. Un essai original est proposé pour étudier l’influence du cyclage de matriçage sur le couplage frottement oxydation et ses conséquences sur l’usure. Un tribomètre spécifique a été développé et mis au point. Les essais de frottement reposent sur une analogie avec le cycle de matriçage, sans reproduire la mise en forme, et un contact conforme favorable à la formation et au piégeage des oxydes / Life time improvement of hot working tools becomes one of the major industrial issue unsufficiently mastered. Indeed, loadings induced by hot forming involve coupling between thermal, mechanical, tribological and physicochemical phenomena. They lead to multiple degradation modes (mainly by plastic deformation, thermo-mechanical fatigue, friction and oxidation). Friction induces one of the most detrimental damage, which is difficult to apprehend and to control allowing for the complexity of engaged couplings.This thesis deals with wear of tool steel X40CrMoV5-1 in the case of hot forging of brass. Damage and wear mechanisms were analyzed through an expertise of matrices after used in production. It reveals different types of damage, activated thanks to location and exposure of the matrix surface to cyclic loadings induced during forging. A scenario of a three-body abrasion is proposed maintained by working cycles and wherein brass and toll steel oxides are crucial.Oxidation and pre-oxidized tribological behavior of tool steel were investigated. An original test is proposed to study the influence of hot working cycling on friction-oxidation coupling and its effects on the wear of tool steel. A specific tribometer has been developed. The friction tests are defined by analogy with the hot-working cycle, without reproducing the forming process, favoring formation and trapping of oxides inside the contact

Este trabalho tem como objetivo o estudo dos coeficientes de atrito obtidos através do ensaio do anel, que é um dos métodos clássicos para verificação e a caracterização do atrito, comparado com a extrusão por duplo copo, DCE (Double Cup Extrusion). Foram feitos ensaios utilizando como material para confecção dos corpos de prova o alumínio AA6351 e variando três situações de lubrificação: teflon, grafite e ensaios sem lubrificação. Para o DCE foi desenvolvido o projeto e fabricação do ferramental, permitindo variar punções de duas dimensões diferentes. Os resultados obtidos nos experimentos com cada uma das técnicas foram comparados e apresentados, traçando-se um paralelo do atrito verificado, bem como o comportamento do material em relação às ferramentas utilizadas nos experimentos e as variações de lubrificação. / This work aims to study the friction coefficients obtained by the ring test, which is one of the classic methods for verification and characterization of friction, compared with DCE (Double Cup Extrusion). The tests were made using as material for preparation of specimens, the aluminum AA6351 and varying three situations lubrication, Teflon, graphite and tests without lubrication. For DCE was developed the design and manufacture of tooling, allowing vary punctures in two differ dimensions. The results obtained in the experiments with each of the techniques have been compared and shown by drawing a parallel scanned the friction and the material behavior in relation to the tools used in the experiments and lubrication changes.

A necessidade de se desenvolver um produto capaz de atingir as exigências impostas pela referência normativa AS-2213 (1984) e a falta de uma rotina de projeto para o componente denominado Garfo do Engate Automático motivam este trabalho. Assim, esta pesquisa apresenta como objetivo principal o estudo de fadiga e estimativa de vida do garfo forjado de um dispositivo de acoplamento automático entre veículos tratores e reboques. Para realização das análises estáticas através de elementos finitos, foi necessária a determinação de todas as condições de contorno que refletissem as características do teste experimental de homologação do produto. De posse destes resultados, realizou-se a análise pelo método S-N, tendo como resultado a determinação da vida em fadiga das regiões críticas do componente, onde são propostas algumas alternativas que visam aumentar a vida do produto. Dentre as inúmeras alternativas possíveis, destacam-se a alteração de material e utilização de tratamento térmico no garfo. / The necessary development of a product capable of reaching the imposed requirements in accordance with reference standard AS-2213 (1984) and the lack of a project routine for the component called Towing Hitch Fork motivated this research. Thus, this research presents as its main goal, the study of fatigue and life predictions of forged fork of the automatic coupling device used in tractor vehicles and trailers. To perform the static analysis through finite elements method, it was necessary to determine all contour conditions which represent the features of product certification tests. After preliminary results have been obtained, the S-N analysis has been performed, showing the fatigue life predictions in the critical regions of the component, where some alternatives aiming at increasing the product life were considered. Among the several alternatives, it is possible to highlight the material changes and the use of thermal treatment in the component.

Este trabalho apresenta um estudo relacionado a três estados de superfície aplicados em um substrato de aço ferramenta AISI H13 temperado e revenido utilizado no processo de calibração a frio para a fabricação de forjados de precisão, os quais posteriormente processados transformam-se em componentes de um semieixo homocinético. O foco deste trabalho foi demostrar através da aplicação de tratamentos de superfície o aumento do desempenho em termos de resistência ao desgaste na interface da superfície da ferramenta em análise e também correlacionar com o seu custo benefício do produto final, visto que o critério para avaliação de vida útil depende diretamente do dimensional final do forjado. Para a comparação e o teste industrial foram estipuladas três condições diferentes de superfície para serem avaliadas. A primeira sem revestimento, a segunda com modificação superficial pelo processo de nitretação gasosa e a terceira com revestimento Dúplex PVD a base de CrTiN. A caracterização das amostras foram realizadas com o auxílio de microscopia eletrônica de varredura, análises metalográficas de microestrutura e dureza. A partir dos resultados obtidos foi constatado que o revestimento Dúplex aplicado em ferramentas para calibração a frio apresentou o melhor desempenho em relação às outras duas condições propostas. O revestimento Dúplex obteve um ganho de 400% em vida útil de ferramentas correlacionado a melhor resistência ao desgaste e, além disso, uma melhor performance em seu comportamento dimensional perante ao processo aplicado. Como segunda alternativa, as ferramentas com o processo de nitretação gasosa atingiram uma redução de 17% nos custos de ferramentas por peças produzidas e acréscimo de 20% em vida útil de ferramentas, apresentando uma melhora em relação as ferramentas sem tratamento de superfície. / This work presents a study related to three surface states applied on a quenching and tempered AISI H13 tool steel substrate used in the cold calibration process for the manufacture of precision forgings, which are subsequently processed into components of a halfshafts. This dissertation aims at demonstrating, through the application of surface treatments, the increase in the wear resistance performance of the tool under analysis and correlating this with cost benefit in the final product, since the end life criterion for the tools depends directly on the dimensions of the forged part. For comparison and industrial testing three different surface conditions were stipulated for evaluation. The first uncoated, the second with surface modification by the gas nitriding process and the third with PVD duplex coating based on CrTiN. The characterization of the samples was carried out with Optical and Scanning Electron Microscopy, Metallographic Analysis of the Microstructure and Hardness Tests. According with obtained results it was verified that the treatment duplex coating applied in tools for cold calibration presented the best performance in relation to the other two conditions proposed. The duplex coating obtained a gain of 400% in tool life correlated to better resistance to wear and, in addition, a better performance in its dimensional behavior in relation to the previous condition without surface treatment. As a second alternative, the tools treated by the gas nitriding process achieved a 17% reduction in tooling costs per parts produced and a 20% increase in tool life, showing an improvement over tools without surface treatment.

A necessidade de se desenvolver um produto capaz de atingir as exigências impostas pela referência normativa AS-2213 (1984) e a falta de uma rotina de projeto para o componente denominado Garfo do Engate Automático motivam este trabalho. Assim, esta pesquisa apresenta como objetivo principal o estudo de fadiga e estimativa de vida do garfo forjado de um dispositivo de acoplamento automático entre veículos tratores e reboques. Para realização das análises estáticas através de elementos finitos, foi necessária a determinação de todas as condições de contorno que refletissem as características do teste experimental de homologação do produto. De posse destes resultados, realizou-se a análise pelo método S-N, tendo como resultado a determinação da vida em fadiga das regiões críticas do componente, onde são propostas algumas alternativas que visam aumentar a vida do produto. Dentre as inúmeras alternativas possíveis, destacam-se a alteração de material e utilização de tratamento térmico no garfo. / The necessary development of a product capable of reaching the imposed requirements in accordance with reference standard AS-2213 (1984) and the lack of a project routine for the component called Towing Hitch Fork motivated this research. Thus, this research presents as its main goal, the study of fatigue and life predictions of forged fork of the automatic coupling device used in tractor vehicles and trailers. To perform the static analysis through finite elements method, it was necessary to determine all contour conditions which represent the features of product certification tests. After preliminary results have been obtained, the S-N analysis has been performed, showing the fatigue life predictions in the critical regions of the component, where some alternatives aiming at increasing the product life were considered. Among the several alternatives, it is possible to highlight the material changes and the use of thermal treatment in the component.

Neste trabalho foram utilizados os conceitos de célula flexível de manufatura e de automação utilizando a robótica para desenvolver uma célula robotizada de acabamento de instrumentos cirúrgicos forjados, com o objetivo de obter aumento de produção e flexibilizar o sistema de manufatura. Na produção manual de acabamento dos instrumentos cirúrgicos incluídos no estudo são realizados processos de lixamento, eletropolimento, polimento vibratório, jateamento e polimento com manta sintética e escova. Foi identificado que o sistema utilizando trabalho manual restringe a produtividade a um número de pinças insuficiente para atender à demanda do mercado. Desse modo, foi desenvolvida uma célula robotizada de acabamento, com a intenção de suprir a necessidade do aumento de produção dos instrumentos cirúrgicos. Em paralelo ao desenvolvimento da célula flexível de manufatura, estudaram-se os processos de acabamento utilizados, resultando na eliminação de etapas de acabamento no processo automatizado. Com a célula flexível de manufatura desenvolvida se obteve um aumento de produção de 96,87 % e uma redução nos custos de 50,53 % em relação à linha manual. Os produtos cuja manufatura se deseja automatizar são pinças hemostáticas, de apreensão e de campo que foram selecionadas através da análise da demanda produtiva. A matéria-prima utilizada nestes instrumentos é aço inoxidável martensítico, de denominação AISI 420D. O processo de fabricação utilizado nos componentes é o forjamento, que permite a melhora das propriedades mecânicas, modificando a disposição dos constituintes do material deformado. No entanto, foi avaliada de forma experimental a viabilidade de substituição do forjamento pelo corte laser, visando a eliminação do processo de lixamento dos componentes, com consequente aumento na taxa de produção, o que não foi possível devido à menor resistência obtida pelos componentes assim produzidos. / In this study, were used the concepts of flexible cell manufacturing and automation using robotics to develop a finishing in forged surgical instruments robot cell, in order to get increased production and a more flexible manufacturing system. On completion of the manual production of surgical instruments included in the study of processes are performed grinding, electropolishing, vibratory polishing, sandblasting and polishing synthetic blanket and brush. Was identified that the system using manual labor productivity to a limited number of tweezers insufficient to meet market demand. Thus, was developed a robotic finishing cell, with the intention of meeting the need for increasing production of surgical instruments. In parallel to the development of flexible manufacturing cell, were studied the finishing processes used, resulting in the elimination of finishing steps in the automated process. With the flexible manufacturing cell development was obtained an increase of 96.87% and production cost savings of 50.53% compared to the online manual. The products whose manufacture is desirable to automate hemostat, apprehension and field tweezers that were selected by analyzing the production demand. The raw material used in these instruments is martensitic stainless steel, designations AISI 420D. The manufacturing process used in the components is forginig, which allows the improvement of mechanical properties by modifying the arrangement of the constituents of the deformed material. However, it was experimentally evaluated the feasibility of replacing the forging by laser cutting, in order to eliminate the process of grinding the components, with consequent increase in production rate, which was not possible due to a lower resistance obtained by the components thus produced.