Results of simulation of orbital forging are compared in the present work with the result obtained from a conventional. Upset forging increases the diameter of the work piece by compressing its length. Semiatin, air force research laboratory, materials and manufacturing directorate. In cold orbital forging of gear rack, the axial deformation along its axis is not expected but the radial deformation is expected to form the teeth. The orbital cold forging process by nature, like other incremental forming processes, is exceptionally difficult to model because of its nonlinearity in geometry, material and contact conditions. Forging is a manufacturing process involving the shaping of metal using localized compressive forces. The main subject of the present work is investigation of possibility of extension of classical orbital forging technology to obtain more cost effective forging process. Rotary forging rotary forging, or orbital forging, is a twodie forging process that deforms only a small portion of the workpiece at a time in a continuous manner. Recent development in orbital forging technology springerlink. A new punch profile design for orbital forging of a bevel. I made the animation on drop forging and press forging process so hope you will like this. Unfortunately, the term rotary forging is sometimes used to describe the process that is more commonly referred to as radial forging, causing some confusion in terminology. A 3d dynamic explicit fe model is developed for numerical simulation of orbital cold forging of a spur bevel gear using the abaqusexplicit.
Introduction the orbital forging is a method of cold or worm. Forging process is operated by hammering or pressing the metal. In order for orbital forging to be optimum a number of factors need to be controlled, just one example being the workpiece material including chemical composition, microstructure and deformability. Introduction the finite element simulation technique has been a popular and powerful tool to improve the forging sequences and the quality of forgings at industry. Pdf recent development in orbital forging technology. A staple of the modern welding skill set, its vital for those in the industry to understand and maintain awareness of, and learning this specialty can help you get ahead in your welding career. Orbital headforming machines have been used to assemble a variety of stamped and blanked components for 30 years. Based on number of pieces produced this is the most widely used forging process. Proceedings of 7th thirf international conference, 27 april2014, pune, india, isbn. The finite element model was developed and used in research on possibility of modification of the classical orbital forging technology based on the marciniak press to obtain more effective process. The orbital forging process is intended to allow smaller machines to be used for suitable forging operations.
Special incremental motion enables smaller contact area between tool and workpiece and therefore, lower forming load and friction. The orbital forging is one of the metal forming processes which enables the manufacture of products through worm or cold working. A characteristic feature of this technological process is the use of a special wobbling motion of one of the tools. Development of orbital forging processes by using marciniak. Recent development in orbital forging technology core. There are a numbers of parameters that influence orbital forging process and thereby, the quality of final product. Reduced oxide scale formation compared with hot forging applications. It is employed to convert metal ingots to simple stock members like blooms, billets, slabs, sheets, plates, strips etc. In these days some suitable capacities for forging heavy forged pieces can be found out in japan japan steel works, in china china first heavy industries and china erzhong in.
Mar 05, 2018 forging process animation in this video we are going t discuss about forging process. The analysis focuses on the pattern of material flow, accuracy of the shape of the produced workpiece, as well as. Rolling is the most widely used metal forming process. Orbital forging should produce 25% material savings and 50% reduced energy costs. The geometry of the forged bevel gear are divided into characteristic features. Often, it can be used as an alternative to conventional staking, peening, crimping, pressing, swaging, spinning, rolling, riveting, welding, upsetting, and other fastening operations. Preform designing approach in cold orbital forging of. Even though roll forging uses rolls in order to accomplish the deformation of the material, it is classified as a metal forging process and not a rolling process.
The material flow analysis in the modified orbital forging. Results of simulation of orbital forging are compared in the present work with the result. The experiments are also performed and the preform designing approach in cold orbital forging of flange gear is verified. With the introduction of flexible manufacturing and advanced productivity concepts, including justintime jit manufacturing and measurable process control, the use of orbital headforming in production is increasing.
Forging is often classified according to the temperature at which it is performed. Studies on stress and strain state in cold orbital forging a almgsi. Forging is one of the oldest forms of metalworking. Orbital forcing is the effect on climate of slow changes in the tilt of the earths axis and shape of the orbit see milankovitch cycles.
The process of shaping metals into semifinished or finished forms by passing between rollers is called rolling. The difficulty in forging of bevel gear with an outside diameter larger than 75mm is due to the high forming load requirement. Roll forging or roll forming is a forging technique that utilizes opposing rolls to shape a metal part. A numerical model of orbital forging process numerical analysis was performed using the. It is one of the oldest metalworking arts with its origin about some thousands of years back. Obtained numerical results from simulations of the new orbital process are compared. Semiatin, air force research laboratory, materials and manufacturing directorate metalworking consists of deformation processes in which a metal billet or blank is shapedbytoolsordies. Forging manipulators have become commonplace even in the largest forging presses. Drawbacks of orbital forging are longer process times, as is usual with incremental forging processes. Thedesignandcontrolof such processes depend on the characteristics of the workpiece material, the conditions at the. In this context, the term forcing signifies a physical process that.
The geometric scheme of a model of the orbital forging process is shown in figure 2. Furthermore, numerical analysis of the process has been conducted in order to predict forming load. Cold and hot forging fundamentals and applications edited by taylan altan, ercnsm, ohio state university gracious ngaile, north carolina state university. Some examples of shapes obtained by forging process. This process is based on the simple concept that the axial force required to effect a desired deforming zone between the platens is confined to a small region. Orbital headforming, which is sometimes called orbital forming, is a clean, silent, nonimpact, and vibrationfree cold forming process. In figure 2b typical tool configuration of orbital forging is presented. In our latest video we discuss the uses and differences between cold, warm, and hot forging. The applications of 2d fem to practical industrial. Orbital forging is the process used for forging of shaped parts by applying the incremental forging method. Thus, this study showed that 3d fem is a reasonably reliable tool for process design in orbital forming. Crane hook, connecting rod of ic engine, spanner, gear blanks etc.
As metal is shaped during the forging process, its internal grain structure deforms to follow the general shape of the part or component. The difference in cold, warm, and hot forging youtube. Numerical investigation of producing a ti6al4v alloy jaw. Therefore, cold forging becomes feasible in cases where traditional forging processes would require a hot forging operation. Each of these processes have advantages but also have limitations. These orbital changes change the total amount of sunlight reaching the earth by up to 25% at midlatitudes from 400 to 500 wm. A few examples of common parts produced using the upset forging process are engine valves, couplings, bolts, screws, and other fasteners. The term orbital welding is an important subject matter when discussing welding or manufacturing. Orbital forging is a relatively new technology in which parts are produced by specific movement of tools. Various forging operations hubbing process consists of pressing a hardened punch with a tip geometry into the surface of a block of metal hubbing force can be estimated from 3utsa uts is obtained from table 2. Orbital forming technology a lot of performance with little force feintools orbital forming technology helps you achieve your metal forming production targets more quickly than other processes. In fact, forging is often the optimum process, in terms of both part quality and cost, especially for applications that require maximum part strength, custom sizes or.
The forging process is ideally suited to many part applications. The orbital forging is a method of cold or worm working of parts, which is based on methods patented in 1920 by slick followed by massey 1922 massey. The hot orbital forging process is run using an industrial orbital forging press, mcof 4000. Thickness tolerances on warm forging of steel at 700800.
Then, the cold orbital forging processes are simulated under different preform geometries and the insufficient filling and folding defects are studied. The orbital forging is one of the metal forming processes which enables the manufacture of. After each forging, the component is hot cropped off the end of the bar and is replaced in the slot heater or induction heater to reheat the end of the bar. It is one of the oldest known metalworking processes with its origin about some thousands of years ago. Hence, orbital forging in some cases makes it possible to. Forging process animation in this video we are going t discuss about forging process. Orbital forging orbital forging is a twodie forging process that deforms only a small portion of the workpiece at a time in a continuous manner. Oct 11, 2018 in our latest video we discuss the uses and differences between cold, warm, and hot forging. The preheating forging metal temperature range for most alloys is relatively narrow, generally555 c5100 f,andfornoalloyisthe range greater than 85 c 155 f. As a result of this the area of contact between work and punch is reduced.
However, due to specific motion of the tools, orbital forging is a slower process and requires significantly more complex machine design. Therefore, the rocking axis is designed to be parallel to the axis of gear rack, i. Depending on such factors as complex multisegmented precision. Preform designing approach in cold orbital forging of flange. Forging process animation by basic engineering youtube. Stresses beyond yield strength of the workpiece material is required. How orbital forming works in orbital forming, the forming force is only exerted on part of the surface of the workpiece. At last, the preform is optimized and the defects are eliminated. Results of simulation of orbital forging are compared in the present work with the result obtained from a conventional forging process. Achieving and maintaining proper preheating metal temperatures in the forging of aluminum alloys is a critical process variable that is vital to the success of the forging process. The main aim of this work is the computer aided design of the new orbital forging process. Metal forming processes indian institute of technology. Precision forging, or netshape forging, has become increasingly popular with. Rotary forging, or orbital forging, is a twodie forging process that deforms only a small portion of the workpiece at a time in a continuous manner.
Thus, the forging force is applied only to a limited area of the workpiece surface at a given time and the required force could be substantially lower as comparing to conventional forging where a whole workpiece is deformed at once. Orbital welding, simply explained, is a way to join two objects together by. In this process the punch is given orbital rocking motion while pressing the workpiece. Orbital forging orbital forging is a twodie forging process that deforms only a small portion of the workpiece at a time in a.