Improvement of the Technology of Precision Forging of Connecting Rod-Type Forgings in a Multiple System, in the Aspect of the Possibilities of Process Robotization by Means of Numerical Modeling
The study refers to the application of numerical modeling for the improvement of the currently realized precision forging technology performed on a hammer to produce connecting rod forgings in a triple system through the development of an additional rolling pass to be used before the roughing operat...
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| Format: | Article |
| Language: | English |
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MDPI AG
2024-02-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/17/5/1087 |
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| author | Marek Hawryluk Łukasz Dudkiewicz Sławomir Polak Artur Barełkowski Adrian Miżejewski Tatiana Szymańska |
| author_facet | Marek Hawryluk Łukasz Dudkiewicz Sławomir Polak Artur Barełkowski Adrian Miżejewski Tatiana Szymańska |
| author_sort | Marek Hawryluk |
| collection | DOAJ |
| description | The study refers to the application of numerical modeling for the improvement of the currently realized precision forging technology performed on a hammer to produce connecting rod forgings in a triple system through the development of an additional rolling pass to be used before the roughing operation as well as preparation of the charge to be held by the robot’s grippers in order to implement future process robotization. The studies included an analysis of the present forging technology together with the dimension–shape requirements for the forgings, which constituted the basis for the construction and development of a thermo-mechanical numerical model as well as the design of the tool construction with the consideration of the additional rolling pass with the use of the calculation package Forge 3.0 NxT. The following stage of research was the realization of multi-variant numerical simulations of the newly developed forging process with the consideration of robotization, as a result of which the following were obtained: proper filling of the tool impressions (including the roller’s impression) by the deformed material, the temperature distributions for the forging and the tools as well as plastic deformations (considering the thermally activated phenomena), changes in the grain size as well as the forging force and energy courses. The obtained results were verified under industrial conditions and correlated with respect to the forgings obtained in the technology applied so far. The achieved results of technological tests confirmed that the changes introduced into the tool construction and the preform geometry reduced the diameter, and thus also the volume, of the charge as well as provided a possibility of implementing robotization and automatization of the forging process in the future. The obtained results showed that the introduction of an additional rolling blank resulted in a reduction in forging forces and energy by 30% while reducing the hammer blow by one. Attempts to implement robotization into the process were successful and did not adversely affect the geometry or quality of forgings, increasing production efficiency. |
| first_indexed | 2024-04-25T00:25:57Z |
| format | Article |
| id | doaj.art-da42456c2d21486da14d61f126f68ec7 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-04-25T00:25:57Z |
| publishDate | 2024-02-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-da42456c2d21486da14d61f126f68ec72024-03-12T16:49:13ZengMDPI AGMaterials1996-19442024-02-01175108710.3390/ma17051087Improvement of the Technology of Precision Forging of Connecting Rod-Type Forgings in a Multiple System, in the Aspect of the Possibilities of Process Robotization by Means of Numerical ModelingMarek Hawryluk0Łukasz Dudkiewicz1Sławomir Polak2Artur Barełkowski3Adrian Miżejewski4Tatiana Szymańska5Department of Metal Forming, Welding and Metrology, Wroclaw University of Science and Technology, Lukasiewicza Street 5, 50-370 Wroclaw, PolandDepartment of Metal Forming, Welding and Metrology, Wroclaw University of Science and Technology, Lukasiewicza Street 5, 50-370 Wroclaw, PolandDepartment of Metal Forming, Welding and Metrology, Wroclaw University of Science and Technology, Lukasiewicza Street 5, 50-370 Wroclaw, PolandDepartment of Metal Forming, Welding and Metrology, Wroclaw University of Science and Technology, Lukasiewicza Street 5, 50-370 Wroclaw, PolandSchraner Polska, Lotnicza Street 21G, 99-100 Łęczyca, PolandSchraner Polska, Lotnicza Street 21G, 99-100 Łęczyca, PolandThe study refers to the application of numerical modeling for the improvement of the currently realized precision forging technology performed on a hammer to produce connecting rod forgings in a triple system through the development of an additional rolling pass to be used before the roughing operation as well as preparation of the charge to be held by the robot’s grippers in order to implement future process robotization. The studies included an analysis of the present forging technology together with the dimension–shape requirements for the forgings, which constituted the basis for the construction and development of a thermo-mechanical numerical model as well as the design of the tool construction with the consideration of the additional rolling pass with the use of the calculation package Forge 3.0 NxT. The following stage of research was the realization of multi-variant numerical simulations of the newly developed forging process with the consideration of robotization, as a result of which the following were obtained: proper filling of the tool impressions (including the roller’s impression) by the deformed material, the temperature distributions for the forging and the tools as well as plastic deformations (considering the thermally activated phenomena), changes in the grain size as well as the forging force and energy courses. The obtained results were verified under industrial conditions and correlated with respect to the forgings obtained in the technology applied so far. The achieved results of technological tests confirmed that the changes introduced into the tool construction and the preform geometry reduced the diameter, and thus also the volume, of the charge as well as provided a possibility of implementing robotization and automatization of the forging process in the future. The obtained results showed that the introduction of an additional rolling blank resulted in a reduction in forging forces and energy by 30% while reducing the hammer blow by one. Attempts to implement robotization into the process were successful and did not adversely affect the geometry or quality of forgings, increasing production efficiency.https://www.mdpi.com/1996-1944/17/5/1087hammer precision forgingforging FEM modelingrobotizationtechnology improvement |
| spellingShingle | Marek Hawryluk Łukasz Dudkiewicz Sławomir Polak Artur Barełkowski Adrian Miżejewski Tatiana Szymańska Improvement of the Technology of Precision Forging of Connecting Rod-Type Forgings in a Multiple System, in the Aspect of the Possibilities of Process Robotization by Means of Numerical Modeling Materials hammer precision forging forging FEM modeling robotization technology improvement |
| title | Improvement of the Technology of Precision Forging of Connecting Rod-Type Forgings in a Multiple System, in the Aspect of the Possibilities of Process Robotization by Means of Numerical Modeling |
| title_full | Improvement of the Technology of Precision Forging of Connecting Rod-Type Forgings in a Multiple System, in the Aspect of the Possibilities of Process Robotization by Means of Numerical Modeling |
| title_fullStr | Improvement of the Technology of Precision Forging of Connecting Rod-Type Forgings in a Multiple System, in the Aspect of the Possibilities of Process Robotization by Means of Numerical Modeling |
| title_full_unstemmed | Improvement of the Technology of Precision Forging of Connecting Rod-Type Forgings in a Multiple System, in the Aspect of the Possibilities of Process Robotization by Means of Numerical Modeling |
| title_short | Improvement of the Technology of Precision Forging of Connecting Rod-Type Forgings in a Multiple System, in the Aspect of the Possibilities of Process Robotization by Means of Numerical Modeling |
| title_sort | improvement of the technology of precision forging of connecting rod type forgings in a multiple system in the aspect of the possibilities of process robotization by means of numerical modeling |
| topic | hammer precision forging forging FEM modeling robotization technology improvement |
| url | https://www.mdpi.com/1996-1944/17/5/1087 |
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