Study on Mandrel Forging and Necking Process of a Hollow Shaft with an Inner Stepped Hole
Abstract
:1. Introduction
2. Preforming Design Method
3. Numerical Simulation Model and Experimental Procedure
3.1. Establishment of Numerical Simulation Model
3.2. Experimental Procedure
4. Results and Discussion
4.1. Single-Step Pressing Deformation Analysis
4.2. The Effect of the Pressing Reduction
4.3. The Effect of the Rotation Angle
4.4. The Parameters of the Preform
4.5. The Shrinkage Ratio Experiment
5. Conclusions
- An advanced MFN process was proposed for the production of a hollow shaft with an inner stepped hole. The outer stepped hollow shaft was preformed by using a mandrel with the same large hole size, and then the inner stepped hollow shaft was formed by the MFN process using a stepped mandrel with the same size as the inner hole of the target forging.
- The isometric radius difference of the preforming design method was obtained. The radius difference of the outer stepped preform was identical to that of the hollow shaft with inner stepped hole. The relationship between the size of the preform and the target forging was established.
- The law of single-step pressing deformation of the MFN process was analyzed. The deformation morphology was divided into six deformation zones. The deformation of each zone was clearly identified to facilitate the subsequent analysis.
- The parameters of the MFN process were optimized. The pressing reduction was controlled at about 20% of the wall thickness, and the 12 × 30° of rotation angle scheme was utilized. The pressing reduction could be appropriately increased in the third and ninth passes according to the actual inner hole distortion. It guaranteed the quality of the MFN process and eliminated surface-folding defects.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Scheme | R1/mm | ∆R/mm | S/mm | ∆S/mm |
---|---|---|---|---|
K1 | 650 | 100 | 804 | 146 |
K2 | 700 | 150 | 656 | 294 |
K3 | 750 | 200 | 548 | 402 |
Parameters | Value |
---|---|
Mesh number for billet | 150,000 |
Forging temperature | Billet temperature: 1200 °C Anvils temperature: 300 °C |
Heat transfer coefficient | Billet and atmosphere: 10 W/(m2·°C) Billet and anvils: 20,000 W/(m2·°C) |
Friction factor | 0.4 |
Pressing velocity | 40 mm/s |
Pressing interval | 5 s |
Scheme | Pressing Method | Outer Diameter/mm | Outer Diameter Difference/mm | Inner Diameter/mm | Inner Diameter Difference/mm |
---|---|---|---|---|---|
M1 | 6 × 60° | Max: Φ1375 Min: Φ1315 | 60 | Max: Φ685 Min: Φ655 | 30 |
M2 | 8 × 45° | Max: Φ1365 Min: Φ1322 | 43 | Max: Φ680 Min: Φ662 | 18 |
M3 | 12 × 30° | Max: Φ1357 Min: Φ1320 | 37 | Max: Φ675 Min: Φ661 | 14 |
One Loop | Two Loops | Three Loops | Four Loops | |
---|---|---|---|---|
Simulated outer diameter/mm | 1324.97 | 1274.04 | 1191.15 | 1108.21 |
Simulated inner diameter/mm | 629.44 | 543.47 | 476.93 | 404.61 |
Experimental outer diameter/mm | 51.98 | 49.06 | 46.80 | 43.30 |
Experimental inner diameter/mm | 25.30 | 21.90 | 17.92 | 16.46 |
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Ge, X.; Tian, C.; Lu, Y.; Wang, G. Study on Mandrel Forging and Necking Process of a Hollow Shaft with an Inner Stepped Hole. Materials 2022, 15, 5431. https://doi.org/10.3390/ma15155431
Ge X, Tian C, Lu Y, Wang G. Study on Mandrel Forging and Necking Process of a Hollow Shaft with an Inner Stepped Hole. Materials. 2022; 15(15):5431. https://doi.org/10.3390/ma15155431
Chicago/Turabian StyleGe, Xiqing, Chensheng Tian, Yupeng Lu, and Guangchun Wang. 2022. "Study on Mandrel Forging and Necking Process of a Hollow Shaft with an Inner Stepped Hole" Materials 15, no. 15: 5431. https://doi.org/10.3390/ma15155431