Eaton Kick Off Meeting OSU (1)

7/27/2019 Eaton Kick Off Meeting OSU (1)

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ERC

NSM

© Copyright Engineering Research Center for Net Shape Manufacturing, 2005. All rights reserved. Slide 1

Research and Development inForging at ERC/NSM

Dr. Taylan Altan, Professor and Director, [email protected]

Ms. Linda Anastasi, Office Secretary, [email protected]

Center for Precision Forming (CPF)

Engineering Research Center for Net Shape Manufacturing (ERC/NSM)

Columbus, Ohio, USA

Phone: 614-292-9267, Fax: 614-292-7219

www.ercnsm.org & www.cpforming.org



ERC

NSM

© Copyright Engineering Research Center for Net Shape Manufacturing, 2005. All rights reserved.

ERC/NSM Webpage

Slide 2



ERC

NSM

© Copyright Engineering Research Center for Net Shape Manufacturing, 2005. All rights reserved.

Organization Structure

ERC/NSM The Ohio State University

Dr. Taylan Altan, Professor and Director

Government agencies Department of Energy Department of Defense National Science Foundation

Individual companies from countries U.S.A, Germany, Japan, France Spain, New Zealand, Canada

Graduate students

Students pursuing Masters and Ph.D degree at The Ohio state university

Visiting Scholars

Students pursuing Dipl-Ing and Ph.D degree at other universities in Europe

Slide 3



ERC

NSM


ERC/NSM Activities

Stamping Hydroforming MachiningForging

Research for Industry and Government

1) Material characterization <flow stress & formability>

2) Tribology < friction,lubrication & wear >

3) Process Modeling (FEA)/Tool and Process Design

4) Short Courses/Training for Industry and Students



ERC

NSM


ERC/NSM Activities

Stamping Hydroforming MachiningForging

Research for Industry and Government



ERC

NSM


ERC/NSM Activities in Forging

1. Materials Determination of material flow stress data by cylinder compression tests.

2. Tribology (Friction, Tool Wear) Performance evaluation of cold forging lubricants.

Die Failure (Wear/ Fracture) Prediction

3. Process Modeling / Tool and Process Design

• 3D Simulation of Aircraft Structural Components.

• Forging of Internal Combustion Engine Pistons from Aluminum Alloys.

• Multiple Action Cold Forging of Complex Shaped Parts

• Prediction and Reduction of Die Failure in Precision Hot Forging

• Simulation to Compare Surface Quality in Billet Shearing

•Improvement in Tool Life for Cold Header Tooling

• Prevention of Ductile Fracture (Chevron Cracks)

• Stress Analysis and Evaluation of the Bullet Crimping Process

• Three Dimensional Finite Element Simulation of Orbital Forming of Spindle/Bearing Assembly

• Microforming of Medical Devices



ERC

NSM


1.Materials/ Compression Test Tooling

Upper plate

Carbide inserts

Load-cell 1

(200 T)

Load-cell 2

(15 T)

Lower plate



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1. Materials/ Deformed billets

Height

reduction =44.5%

Height

reduction =52%

Height

reduction =62%

Height

reduction =33%

Micrographs of side surface after deformation

0.01 mm



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1. Materials/ Test Results

- Flow stress at different reductions -

Flow Stress Curves-As Received Begin

0

20000

40000

60000

80000

100000

120000

0 0.2 0.4 0.6 0.8 1 1.2

Strain

S t r e s s ( p s i )

Height reduction=33%

Height reduction=44.5%

Height reduction=52%

Height reduction=67%Reduction=33%

Reduction=44.5%

Reduction=52%

Reduction=67%



ERC

NSM


1. Materials/ Test Results

- Flow stress Curve -

Flow Stress Curve

0

20000

40000

60000

80000

100000

120000

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7Strain

S t r e s s ( p s i )

From Experiment

From Equation

K= 117 Ksi, n=0.18 determined by least square fit

18.0117



ERC

NSM


Tribology (Friction, Tool Wear) Performance evaluation of cold forging lubricants by the double

cup extrusion test.

Evaluation of alternative lubricants for replacement of zinc

phosphate coating based lubricants.

Wear and Fracture prediction using FEM simulation.

2. Tribology



ERC

NSM


2. Tribology/ Double Cup

Extrusion Tooling

Double cup extrusion tooling with lower punch at

its upper position for billet removal.



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NSM


Double cup extrusion tooling (sectional view).

2. Tribology/ Double Cup Extrusion

Tooling



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2. Tribology/ Test Results

Initial billet Formed billet

h1

h2

• Ranking the lubricants based on cup height ratio h1/h2

• Surface analysis is done on the cut specimen to investigate galling

• Coefficient of Friction can be determined



ERC

NSM


2. Tribology/ Tested Lubricants

Three lubricant candidates for replacement of zinc phosphate

coating based lubricants were tested.

• MEC Homat

• Daido

• Metal Coating International (MCI)

• Zinc Phosphate Coating ( Control lubricant )



ERC

NSM


2. Tribology/ Lubricant Performance

Friction factor obtained for different lubricants

0.035

0.075

0.068

0.04

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

Mec Homat MCI Phoscoating Daido

Lubricants

F r i c t i o n f a c t o r ( m

)



ERC

NSM


2. Tribology/ Die Failure Prediction

• Die Wear (Abrasive)

• Archard’s Model:

• Behrens’ Model: vdtH(time)

PK W

a

dt(time)H

vPK W

c

ba

Where:

W= Amount of Wear

K= Process Wear CoefficientP= Normal Pressure

v= Sliding Velocity

H= Hardness of the Die

dt= Time Interval

a, b, c= experimental constants

Current Work being done by:

Adam Groseclose, GRA ([email protected])

Dr. Changhyok Choi, Visiting Scholar ([email protected])



ERC

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R

Z

2. Tribology/Die Failure Prediction (Abrasive Wear)



ERC

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2. Tribology/Die Failure Prediction (Fatigue Fracture)

386MPaFatigue Fracture is predicted,

using Deform 2D, to be in the

same region as experimentally

determined.

The stresses of the region

were found to be tensile, which

would cause a fatigue loading

and eventual fracture.

• Die Fracture (Fatigue)



ERC

NSM


• 3D Simulation of Aircraft Structural Components.

• Forging of Internal Combustion Engine Pistons from Aluminum Alloys.

• Multiple Action Cold Forging of Complex Shaped Parts

• Prediction and Reduction of Die Failure in Precision Hot Forging

• Simulation to Compare Surface Quality in Billet Shearing

• Improvement in Tool Life for Cold Header Tooling

• Prevention of Ductile Fracture (Chevron Cracks)

• Stress Analysis and Evaluation of the Bullet Crimping Process

• Three Dimensional Finite Element Simulation of Orbital Forming of

Spindle/Bearing Assembly

• Microforming of Medical Devices

3. Process Modeling and

Development



ERC

NSM

© Copyright Engineering Research Center for Net Shape Manufacturing, 2005. All rights reserved. Slide 21Forging sequence for the aircraft wheel.

3. Process Modeling/

Simulation of Aircraft Wheel

http://localhost/var/www/apps/conversion/tmp/scratch_1/Aida%20PPT/wheel%20finish.avi

http://localhost/var/www/apps/conversion/tmp/scratch_1/Aida%20PPT/wheelStage2.AVI

http://localhost/var/www/apps/conversion/tmp/scratch_1/Aida%20PPT/wheelstage1.avi

http://localhost/var/www/apps/conversion/tmp/scratch_1/Aida%20PPT/wheelstage1.avi



ERC

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Simulation of Aircraft Wheel

Software: DEFORM 3D

Part: Aircraft Wheel

Size: Diameter – 560 mm;

Height – 216 mm

Stage: Preforming

Material: AA 2014

Initial Temperature:

• Dies = 700oF

• Billet = 700oF



ERC

NSM

© Copyright Engineering Research Center for Net Shape Manufacturing, 2005. All rights reserved. Slide 23Forging sequence for an aircraft fitting.


Simulation of Aircraft Fitting



ERC

NSM



Simulation of Aircraft Fitting

Software: DEFORM 3D

Part: Aircraft Fitting

Size: 28” x 4” x 4”

Stage: Preforming

Material: Ti – 6Al – 4V

Initial Temperature:

• Dies = 600o F

• Billet = 1750o F



ERC

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Forging of an Automotive Component

Hot forging of an automotive component.



ERC

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Simulation of Flashless Forging

Flashless forging of a connecting rod.



ERC

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3. Process Modeling/Forging of IC Engine Piston for Racing

Forging of a race-car Al alloy piston.



ERC

NSM

© Copyright Engineering Research Center for Net Shape Manufacturing, 2005. All rights reserved. Slide 28Cross groove inner race of a constant velocity joint.

3. Process Modeling/Cold Forging Using Multiple Action Tooling



ERC

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3. Process Modeling/Cold Forging Using Multiple Action Tooling



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Simulation of Billet Shearing

Billet shearing with element deletion.

C



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3-D Simulation of Billet Shearing

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Prediction of Chevron Cracks

Prediction of chevron cracks during forward extrusion.

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3 P M d li /



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Orbital Forming

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Orbital Forming

Stress contour during orbital forming.

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3 P M d li /



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Micro - Forming

Microforming of cutting blades

(Part thickness = 0.1 mm; flash thickness = 0.01 mm ).

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3 P M d li /



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Micro - Forming

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3 Process Modeling/



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3. Process Modeling/ Assembly of Tubular Components by

Mechanical Crimping

Application to bullet crimping with a mechanical tool.

ERC3 Process Modeling/



ERC

NSM

© Copyright Engineering Research Center for Net Shape Manufacturing, 2005. All rights reserved. Slide 38Simulation of bullet pullout test (test of crimp quality).

3. Process Modeling/ Assembly of Tubular Components by

Mechanical Crimping

ERC3 Process Modeling/



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3. Process Modeling/ Assembly of Tubular Components by Hydraulic

Crimping

Application to bullet crimping with a rubber tool.

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3 Process Modeling/



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Si l ti f b ll t ll t t t (t t f i lit )

3. Process Modeling/ Assembly of Tubular Components by Hydraulic

Crimping

Eaton Kick Off Meeting OSU (1)

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