Mo element was added to cobalt-based alloy L605,and cold forging deformation was performed.The effects of the addition and cold forging deformation on the microstructure and mechanical properties of the alloy were stu...Mo element was added to cobalt-based alloy L605,and cold forging deformation was performed.The effects of the addition and cold forging deformation on the microstructure and mechanical properties of the alloy were studied by thermodynamic calculation,electron backscatter diffraction,transmission electron microscopy,and X-ray diffraction.The stacking fault energy(SFE)of the alloy decreased after the addition,and the formation of stacking faults and intersections were promoted to improve the strength and hardness.The tensile strength of the alloy with Mo increased from 1190 to 1702 MPa after 24%cold deformation,producing significant work hardening.The strengthening mechanism is strain-induced martensitic transformation(SIMT)and deformation twinning.The alloy,combined with Mo and after 24%deformation,had both high strength and ductility in comparison with the original cobalt-based alloy L605.This is attributed to the lower SFE which caused the increase in stacking fault density.During the tensile process,theε-hcp phase was easily generated at the stacking fault to reduce the stress concentration and increase the ductility.Controlling SIMT by adjusting the density of stacking faults can improve the mechanical properties of cobalt-based alloys.Theε-hcp phase,the interaction between deformation twins and dislocations,and the interaction between e-hcp phases during cold forging deformation caused local stress concentration,lowering ductility and toughness.展开更多
Effect of controlled rolling and cooling process on the mechanical properties of low carbon cold forging steel was investigated for different processing parameters of a laboratory hot rolling mill. The results show th...Effect of controlled rolling and cooling process on the mechanical properties of low carbon cold forging steel was investigated for different processing parameters of a laboratory hot rolling mill. The results show that the specimens with fast cooling after hot rolling exhibit very good mechanical properties, and the improvement of the mechanical properties can be attributed mainly to the ferrite-grain refinement. The mechanical properties increase with decreasing final cooling temperature within the range from 670 ℃ to 570 ℃ due to the finer interlamellar spacing of pearlite colony. The specimen with fast cooling after low temperature rolling shows the highest values of the mechanical properties. The effect of the ferrite grain size on the mechanical properties was greater than that of pearlite morphology in the present study. The mechanical properties of specimens by controlled rolling and cooling process without thermal treatment were greatly superior to that of the same specimens by the conventional rolling, and their tensile strength reached 490 MPa grade even in the case of low temperature rolling without controlled rolling. It might be expected to realize the substitution medium-carbon by low-carbon for 490 MPa grade cold forging steel with controlled rolling and cooling process.展开更多
The closed-died cold forging technology of the bevel gears used in Jada car was investigated. With the analysis of the strain field and velocity field of the plastic deformation and the endured forces of the dies, the...The closed-died cold forging technology of the bevel gears used in Jada car was investigated. With the analysis of the strain field and velocity field of the plastic deformation and the endured forces of the dies, the filling rules for the metal were analyzed by the elastic-plastic finite element method （FEM）. The results show that there is a great difference among closed-die cold forging, extrusion and forging, as far as the metal flowing is concerned. The outer addendum cannot be filled completely in the closed-die cold forging of the bevel gears, and the round angle will be formed. But it does not influence the application of the bevel gears. At the beginning, the rigid area is formed in the cavity of the lower die. And then it will move upwards to supply the metal for the gear filling. For the closed-die cold forging of the bevel gears, the force acting on the upper die and the lower die is significantly different.展开更多
Stress analysis and optimization of combined die structure with two stress rings were performed.Using thermoelastic deformation,the contact pressure at the interfaces between layers was calculated.Then,theoretical exp...Stress analysis and optimization of combined die structure with two stress rings were performed.Using thermoelastic deformation,the contact pressure at the interfaces between layers was calculated.Then,theoretical expressions of stress distribution for the combined die were derived.The thermal-mechanical effect under working conditions was considered.To verify the theoretical expressions,simulation work was performed.Optimization of die design was carried out by defining radius ratio and shrink fit coefficient as optimization variables.The objective was to minimize the effective circumferential stress at the inner surface of the die insert,under the constraint that the maximum equivalent stress values of die insert and stress rings did not exceed their respective yield stresses.The Kriging model was used to describe the influence of shrink fit and die dimensions on the objective function and the maximum equivalent stress.Using a genetic algorithm,optimum parameters were found with a minimum circumferential stress of 442.9 MPa under a working stress of 1800 MPa.Further analysis of five selected optimal results was carried out,and the specific design parameters of these combined dies are different under the same level of circumferential stress,and the combined die is overdesigned if the thermal effect is ignored.展开更多
In the present paper,controlled rolling and cooling processing was conducted by using a laboratory hot rolling mill.The influence of different processing parameters on the mechanical properties of low carbon cold forg...In the present paper,controlled rolling and cooling processing was conducted by using a laboratory hot rolling mill.The influence of different processing parameters on the mechanical properties of low carbon cold forging steel was investigated.The results show that the faster cooling after the deformation (especially in low temperature rolling conditions) leads to the refinement of the ferrite grain.The specimen exhibits very good mechanical properties owing to the finer ferrite grains.The pearlite morphologies can also affect the mechanical properties of low carbon cold forging steel.The mechanical properties increase with decreasing final cooling temperature within the range from 650℃ to 570 ℃ due to the finer interlamellar spacing of pearlite colony.The mechanical properties of the specimens with fast cooling after the conventional rolling are not only better than those of the specimens with slow cooling after low temperature rolling,but also almost similar to those of the specimens with fast cooling after low temperature rolling.It is suggested that fast cooling after high temperature rolling (the conventional rolling) process would be of important industrial value.展开更多
The fatigue behavior of cemented carbide die under service load in the multistage cold forging of steel was investigated. It was found that the fatigue cracks do not initiate at the stress concentration position and t...The fatigue behavior of cemented carbide die under service load in the multistage cold forging of steel was investigated. It was found that the fatigue cracks do not initiate at the stress concentration position and the crack initiation position can be classified to three types. The crack initiation position can be predicted by FEM only when the plastic deformation of the die is considered.展开更多
This study evaluated dry-in-place lubricants used for cold forging.A group of isothermal compression tests with a strain rate(ε)e&range of 0.001–1 s^(−1) and temperature(T)range of 30–400℃ were completed.The f...This study evaluated dry-in-place lubricants used for cold forging.A group of isothermal compression tests with a strain rate(ε)e&range of 0.001–1 s^(−1) and temperature(T)range of 30–400℃ were completed.The flow stress(σ)curves of annealed steel S45C were obtained,and a corresponding Hensel–Spittel model was developed to support finite element(FE)simulation.The sensitivity of the steady combined forward and backward extrusion(SCFBE)test proposed in another study was improved by approximately 20%after it was optimized using the results of the FE simulations.Key parameters were identified,and the calibration curves after optimization were obtained.On the basis of the optimized test,a friction testing setup with a heating system was developed,in which the die temperature could be adjusted from room temperature(RT)to 230℃.Three dry-in-place lubricants and conventional phosphating lubricant were tested,and the friction factors(m),forming loads,and ejection loads were measured.The surface features of the specimens after testing were also investigated.According to the testing results,of the three tested dry-in-place lubricants,the mica type was the best.In addition,the optimized friction testing design was verified as effective.展开更多
Based on the design of the multi-row sprocket with a new tooth profile,a cold semi-precision forging process for manufacturing 5052 aluminum alloy multi-row sprocket was presented.Through simulating the forging proces...Based on the design of the multi-row sprocket with a new tooth profile,a cold semi-precision forging process for manufacturing 5052 aluminum alloy multi-row sprocket was presented.Through simulating the forging process of 5052 aluminum alloy sprocket billet with 3D rigid-viscoplastic FEM,both the distributions of flow velocity field in axial(U_Z),radial(U_R) and circumferential(U_θ) directions and the curves of velocity component in different deformation regions were respectively obtained.By comparison and analysis of the velocity varying curves,the velocity component relation conditions for filling the die cavity were clarified.It shows that when the die cavity is almost fully filled,the circumferential velocity U_θ increases sharply,implying that U_θplays a key role in fully filling the die cavity.展开更多
To investigate the effects of billet geometry on the cold precision forging process of a helical gear, six different billet geometries were designed utilizing the relief-hole principle. And the influences of the bille...To investigate the effects of billet geometry on the cold precision forging process of a helical gear, six different billet geometries were designed utilizing the relief-hole principle. And the influences of the billet geometry on the forming load and the deformation uniformity were analyzed by three-dimensional （3D） finite element method （FEM） under the commercial software DEFORM 3D. The billet geometry was optimized to meet lower forming load and better deformation uniformity requirement. Deformation mechanism was studied through the distribution of flow velocity field and effective strain field. The forging experiments of the helical gear were successfully performed using lead material as a model material under the same process conditions used in the FE simulations. The results show that the forming load decreases as the diameter of relief-hole do increases, but the effect of do on the deformation uniformity is very complicated. The forming load is lower and the deformation is more uniform when do is 10 mm.展开更多
The cold semi-precision forging of a multi-row sprocket was investigated using upper-bound （UB） and finite element methods combined with experiments. Based on the design of a new tooth profile for the sprocket, a co...The cold semi-precision forging of a multi-row sprocket was investigated using upper-bound （UB） and finite element methods combined with experiments. Based on the design of a new tooth profile for the sprocket, a cold semi-precision forging process and a kinematically admissible velocity field for filling the die cavity were proposed. Using the UB method, the velocity fields of the sprocket billet in the forming process were divided theoretically and calculated. The process of forging a multi-row sprocket was simulated using the FEM package Deform-3D V6.1 to obtain the distributions of the velocity field and the effective stress field in filling the die cavity. Similar to the simulated results, the experiment on cold forging a 5052 aluminum alloy sprocket was successfully performed. By comparing the calculated （UB method）, experimental and simulated load-stroke curves, the calculated and simulated results were basically in accordance with the experimental results. The study provides a theoretical foundation for the development of the precision forging of multi-row sprockets.展开更多
Forging spur gears are widely used in the driving system of mining machinery and equipment due to their higher strength and dimensional accuracy.For the purpose of precisely calculating the volume of cylindrical spur ...Forging spur gears are widely used in the driving system of mining machinery and equipment due to their higher strength and dimensional accuracy.For the purpose of precisely calculating the volume of cylindrical spur gear billet in cold precision forging,a new theoretical method named average circle method was put forward.With this method,a series of gear billet volumes were calculated.Comparing with the accurate three-dimensional modeling method,the accuracy of average circle method by theoretical calculation was estimated and the maximum relative error of average circle method was less than 1.5%,which was in good agreement with the experimental results.Relative errors of the calculated and the experimental for obtaining the gear billet volumes with reference circle method are larger than those of the average circle method.It shows that average circle method possesses a higher calculation accuracy than reference circle method(traditional method),which should be worth popularizing widely in calculation of spur gear billet volume.展开更多
The cold radial forging process usually introduces some changes of the material, such as the increased strength, the decreased plasticity and the introduction of anisotropic mechanical prop- erty. To obtain the change...The cold radial forging process usually introduces some changes of the material, such as the increased strength, the decreased plasticity and the introduction of anisotropic mechanical prop- erty. To obtain the changes of mechanical property of barrel processed by cold radial forging, the tangential mechanical properties of the barrel blank and the forged barrel are measured with a de- signed test based on the plastic deformation analysis for a barrel and by applying internal pressure, and their axial mechanical properties are measured by the tensile test. The changes of mechanical property of barrel processed by cold radial forging are obtained by comparing the mechanical proper- ties of the barrel blank and the forged barrel. The tangential and axial flow stresses of the barrel blank and the forged barrel are also presented.展开更多
Cold rotary forging is an advanced and complex metal forming technology with continuous local plastic deformation.Investigating the contact force between the dies and the workpiece has a great significance to improve ...Cold rotary forging is an advanced and complex metal forming technology with continuous local plastic deformation.Investigating the contact force between the dies and the workpiece has a great significance to improve the life of the dies in cold rotary forging.The purpose of this work is to reveal the contact force responses in cold rotary forging through the modelling and simulation.For this purpose,a 3D elastic-plastic dynamic explicit FE model of cold rotary forging is developed using the FE code ABAQUS/Explicit.Through the modelling and simulation,the distribution and evolution of the contact force in cold rotary forging is investigated in detail.The experiment has been conducted and the validity of the 3D FE model of cold rotary forging has been verified.The results show that: 1) The contact force distribution is complex and exhibits an obvious non-uniform characteristic in the radial and circumferential directions; 2) The maximum contact force between the upper die and the workpiece is much larger than that between the lower die and the workpiece; 3) The contact force evolution history is periodic and every period experiences three different stages; 4) The total normal contact force is much larger than the total shear contact force at any given time.展开更多
Cold orbital forging is an advanced spur bevel gear forming technology. Generally, the spur bevel gear in the cold orbital forging process is formed by two steps: the preforming step and the final step. Due to the gre...Cold orbital forging is an advanced spur bevel gear forming technology. Generally, the spur bevel gear in the cold orbital forging process is formed by two steps: the preforming step and the final step. Due to the great importance of the final step to gear forming and its complication with interactive factors, this work aims at examining the influence of key factors on the final step in cold orbital forging of a spur bevel gear. Using the finite element(FE) method and control variate method, the influence rules of four key factors, rotation velocity of the upper tool, n, feeding velocity of the lower tool, v, tilted angle of the upper tool, γ, friction factor between the tools and the billet, m, on the geometry and the deformation inhomogeneity of the cold orbital forged gear are thoroughly clarified. The research results show that the flash becomes more homogeneous with increasing v, increasing m, decreasing n or decreasing γ. And the deformation of the gear becomes more homogeneous with increasing v, decreasing n or decreasing γ. Finally, a corresponding experiment is conducted, which verifies the accuracy of FE simulation conclusions.展开更多
Al5A06 sheets by large cold plastic deformation usually have high strength but low plasticity,i.e.weak strength-plasticity matching,which may lead to their poor fatigue property.In this study,annealing treat-ments are...Al5A06 sheets by large cold plastic deformation usually have high strength but low plasticity,i.e.weak strength-plasticity matching,which may lead to their poor fatigue property.In this study,annealing treat-ments are applied on cold rotary forged Al5A06 sheets to regulate strength-plasticity matching and im-prove fatigue properties.The microstructures,tensile mechanical properties and fatigue properties un-der different annealing parameters were analyzed.The abnormal grain growth mechanism of cold rotary forged Al5A06 sheets during 300℃ annealing treatment was investigated,and the fatigue failure mech-anism of Al5A06 sheets with different annealing temperatures was also investigated.The abnormal grain growth during 300℃ annealing treatment is mainly due to the asynchronous recrystallization behavior with low recrystallization driving force,which leads to the early recrystallized regions directly absorb-ing adjacent grains along134crystal direction.The cold rotary forged Al5A06 sheets after 250℃-2 h annealing treatment exhibit the best fatigue property,which is mainly because the optimum strength-plasticity matching brings about coordinate plastic deformation throughout most grains,and the effective dislocation movement between adjacent grains can delay the appearance of strain localization and ac-commodate continuous fatigue cyclic loading.展开更多
Cold closed-die forging is a suitable process to produce spur-bevel gears due to its advantages, such as saving materials and time, reducing costs, increasing die life and improving the quality of the product. The hom...Cold closed-die forging is a suitable process to produce spur-bevel gears due to its advantages, such as saving materials and time, reducing costs, increasing die life and improving the quality of the product. The homogeneity of microstructure of cold closed-die forged gears can highly affect their service performance. The homogeneity of microstructure and Vickers hardness in cold closed-die forged gear of 20 Cr Mn Ti alloy is comprehensively studied by using optical microscopy and Vickers hardness tester. The results show that the distribution homogeneity of the aspect ratio of grain and Vickers hardness is the same. In the circumferential direction of the gear tooth, the distribution of the aspect ratio of grain and Vickers hardness is inhomogeneous and they gradually decrease from the surface to the center of the tooth. In the radial direction, the distribution of the aspect ratio of grain and Vickers hardness is inhomogeneous on the surface of the gear tooth; while it is relatively homogeneous in the center of the gear tooth. In the axial direction of the gear tooth, the distribution of the aspect ratio of grain and Vickers hardness is relatively homogeneous from the small-end to the large-end of the gear tooth.展开更多
The chemical compositions and microstructures of the armor strips excavated from the Emperor Qin Shi Huang's mausoleum were examined systematically by using optical microscopy and electron microscopy.It was found ...The chemical compositions and microstructures of the armor strips excavated from the Emperor Qin Shi Huang's mausoleum were examined systematically by using optical microscopy and electron microscopy.It was found that the armor strips were made of pure copper.Based on the morphology of α-Cu recrystal grain and copper sulphide(Cu2S) inclusions in the armor strips,the manufacturing techniques were proposed as follows:smelting pure copper,casting a lamellar plate,forming the cast ingots into sheets through repeated cold forging combined with annealing heat treatment,and finally cutting the sheets into filaments.Furthermore,through the deformation of copper sulphide(Cu2S) inclusions in the strips,the work rate during forging was evaluated and calculated to be close to 75%.展开更多
基金supported by Program for Young Talents of Science and Technology in Universities of Inner Mongolia Autonomous Region (Grant No.NJYT23115)the Inner Mongolia Natural Science Foundation (Grant No.2022MS05039).
文摘Mo element was added to cobalt-based alloy L605,and cold forging deformation was performed.The effects of the addition and cold forging deformation on the microstructure and mechanical properties of the alloy were studied by thermodynamic calculation,electron backscatter diffraction,transmission electron microscopy,and X-ray diffraction.The stacking fault energy(SFE)of the alloy decreased after the addition,and the formation of stacking faults and intersections were promoted to improve the strength and hardness.The tensile strength of the alloy with Mo increased from 1190 to 1702 MPa after 24%cold deformation,producing significant work hardening.The strengthening mechanism is strain-induced martensitic transformation(SIMT)and deformation twinning.The alloy,combined with Mo and after 24%deformation,had both high strength and ductility in comparison with the original cobalt-based alloy L605.This is attributed to the lower SFE which caused the increase in stacking fault density.During the tensile process,theε-hcp phase was easily generated at the stacking fault to reduce the stress concentration and increase the ductility.Controlling SIMT by adjusting the density of stacking faults can improve the mechanical properties of cobalt-based alloys.Theε-hcp phase,the interaction between deformation twins and dislocations,and the interaction between e-hcp phases during cold forging deformation caused local stress concentration,lowering ductility and toughness.
基金Funded by Shenyang City Application Basic Research Project (No. 1071198-1-00)
文摘Effect of controlled rolling and cooling process on the mechanical properties of low carbon cold forging steel was investigated for different processing parameters of a laboratory hot rolling mill. The results show that the specimens with fast cooling after hot rolling exhibit very good mechanical properties, and the improvement of the mechanical properties can be attributed mainly to the ferrite-grain refinement. The mechanical properties increase with decreasing final cooling temperature within the range from 670 ℃ to 570 ℃ due to the finer interlamellar spacing of pearlite colony. The specimen with fast cooling after low temperature rolling shows the highest values of the mechanical properties. The effect of the ferrite grain size on the mechanical properties was greater than that of pearlite morphology in the present study. The mechanical properties of specimens by controlled rolling and cooling process without thermal treatment were greatly superior to that of the same specimens by the conventional rolling, and their tensile strength reached 490 MPa grade even in the case of low temperature rolling without controlled rolling. It might be expected to realize the substitution medium-carbon by low-carbon for 490 MPa grade cold forging steel with controlled rolling and cooling process.
文摘The closed-died cold forging technology of the bevel gears used in Jada car was investigated. With the analysis of the strain field and velocity field of the plastic deformation and the endured forces of the dies, the filling rules for the metal were analyzed by the elastic-plastic finite element method （FEM）. The results show that there is a great difference among closed-die cold forging, extrusion and forging, as far as the metal flowing is concerned. The outer addendum cannot be filled completely in the closed-die cold forging of the bevel gears, and the round angle will be formed. But it does not influence the application of the bevel gears. At the beginning, the rigid area is formed in the cavity of the lower die. And then it will move upwards to supply the metal for the gear filling. For the closed-die cold forging of the bevel gears, the force acting on the upper die and the lower die is significantly different.
基金the National Natural Science Foundation of China(No.51475294)。
文摘Stress analysis and optimization of combined die structure with two stress rings were performed.Using thermoelastic deformation,the contact pressure at the interfaces between layers was calculated.Then,theoretical expressions of stress distribution for the combined die were derived.The thermal-mechanical effect under working conditions was considered.To verify the theoretical expressions,simulation work was performed.Optimization of die design was carried out by defining radius ratio and shrink fit coefficient as optimization variables.The objective was to minimize the effective circumferential stress at the inner surface of the die insert,under the constraint that the maximum equivalent stress values of die insert and stress rings did not exceed their respective yield stresses.The Kriging model was used to describe the influence of shrink fit and die dimensions on the objective function and the maximum equivalent stress.Using a genetic algorithm,optimum parameters were found with a minimum circumferential stress of 442.9 MPa under a working stress of 1800 MPa.Further analysis of five selected optimal results was carried out,and the specific design parameters of these combined dies are different under the same level of circumferential stress,and the combined die is overdesigned if the thermal effect is ignored.
文摘In the present paper,controlled rolling and cooling processing was conducted by using a laboratory hot rolling mill.The influence of different processing parameters on the mechanical properties of low carbon cold forging steel was investigated.The results show that the faster cooling after the deformation (especially in low temperature rolling conditions) leads to the refinement of the ferrite grain.The specimen exhibits very good mechanical properties owing to the finer ferrite grains.The pearlite morphologies can also affect the mechanical properties of low carbon cold forging steel.The mechanical properties increase with decreasing final cooling temperature within the range from 650℃ to 570 ℃ due to the finer interlamellar spacing of pearlite colony.The mechanical properties of the specimens with fast cooling after the conventional rolling are not only better than those of the specimens with slow cooling after low temperature rolling,but also almost similar to those of the specimens with fast cooling after low temperature rolling.It is suggested that fast cooling after high temperature rolling (the conventional rolling) process would be of important industrial value.
文摘The fatigue behavior of cemented carbide die under service load in the multistage cold forging of steel was investigated. It was found that the fatigue cracks do not initiate at the stress concentration position and the crack initiation position can be classified to three types. The crack initiation position can be predicted by FEM only when the plastic deformation of the die is considered.
基金This research was partially supported by the National Natural Science Foundation of China(NSFC,No.51875348).
文摘This study evaluated dry-in-place lubricants used for cold forging.A group of isothermal compression tests with a strain rate(ε)e&range of 0.001–1 s^(−1) and temperature(T)range of 30–400℃ were completed.The flow stress(σ)curves of annealed steel S45C were obtained,and a corresponding Hensel–Spittel model was developed to support finite element(FE)simulation.The sensitivity of the steady combined forward and backward extrusion(SCFBE)test proposed in another study was improved by approximately 20%after it was optimized using the results of the FE simulations.Key parameters were identified,and the calibration curves after optimization were obtained.On the basis of the optimized test,a friction testing setup with a heating system was developed,in which the die temperature could be adjusted from room temperature(RT)to 230℃.Three dry-in-place lubricants and conventional phosphating lubricant were tested,and the friction factors(m),forming loads,and ejection loads were measured.The surface features of the specimens after testing were also investigated.According to the testing results,of the three tested dry-in-place lubricants,the mica type was the best.In addition,the optimized friction testing design was verified as effective.
基金Projects(51175363,51274149)supported by the National Natural Science Foundation of China
文摘Based on the design of the multi-row sprocket with a new tooth profile,a cold semi-precision forging process for manufacturing 5052 aluminum alloy multi-row sprocket was presented.Through simulating the forging process of 5052 aluminum alloy sprocket billet with 3D rigid-viscoplastic FEM,both the distributions of flow velocity field in axial(U_Z),radial(U_R) and circumferential(U_θ) directions and the curves of velocity component in different deformation regions were respectively obtained.By comparison and analysis of the velocity varying curves,the velocity component relation conditions for filling the die cavity were clarified.It shows that when the die cavity is almost fully filled,the circumferential velocity U_θ increases sharply,implying that U_θplays a key role in fully filling the die cavity.
基金Project(51105287)supported by the National Natural Science Foundation of China
文摘To investigate the effects of billet geometry on the cold precision forging process of a helical gear, six different billet geometries were designed utilizing the relief-hole principle. And the influences of the billet geometry on the forming load and the deformation uniformity were analyzed by three-dimensional （3D） finite element method （FEM） under the commercial software DEFORM 3D. The billet geometry was optimized to meet lower forming load and better deformation uniformity requirement. Deformation mechanism was studied through the distribution of flow velocity field and effective strain field. The forging experiments of the helical gear were successfully performed using lead material as a model material under the same process conditions used in the FE simulations. The results show that the forming load decreases as the diameter of relief-hole do increases, but the effect of do on the deformation uniformity is very complicated. The forming load is lower and the deformation is more uniform when do is 10 mm.
文摘The cold semi-precision forging of a multi-row sprocket was investigated using upper-bound （UB） and finite element methods combined with experiments. Based on the design of a new tooth profile for the sprocket, a cold semi-precision forging process and a kinematically admissible velocity field for filling the die cavity were proposed. Using the UB method, the velocity fields of the sprocket billet in the forming process were divided theoretically and calculated. The process of forging a multi-row sprocket was simulated using the FEM package Deform-3D V6.1 to obtain the distributions of the velocity field and the effective stress field in filling the die cavity. Similar to the simulated results, the experiment on cold forging a 5052 aluminum alloy sprocket was successfully performed. By comparing the calculated （UB method）, experimental and simulated load-stroke curves, the calculated and simulated results were basically in accordance with the experimental results. The study provides a theoretical foundation for the development of the precision forging of multi-row sprockets.
文摘Forging spur gears are widely used in the driving system of mining machinery and equipment due to their higher strength and dimensional accuracy.For the purpose of precisely calculating the volume of cylindrical spur gear billet in cold precision forging,a new theoretical method named average circle method was put forward.With this method,a series of gear billet volumes were calculated.Comparing with the accurate three-dimensional modeling method,the accuracy of average circle method by theoretical calculation was estimated and the maximum relative error of average circle method was less than 1.5%,which was in good agreement with the experimental results.Relative errors of the calculated and the experimental for obtaining the gear billet volumes with reference circle method are larger than those of the average circle method.It shows that average circle method possesses a higher calculation accuracy than reference circle method(traditional method),which should be worth popularizing widely in calculation of spur gear billet volume.
文摘The cold radial forging process usually introduces some changes of the material, such as the increased strength, the decreased plasticity and the introduction of anisotropic mechanical prop- erty. To obtain the changes of mechanical property of barrel processed by cold radial forging, the tangential mechanical properties of the barrel blank and the forged barrel are measured with a de- signed test based on the plastic deformation analysis for a barrel and by applying internal pressure, and their axial mechanical properties are measured by the tensile test. The changes of mechanical property of barrel processed by cold radial forging are obtained by comparing the mechanical proper- ties of the barrel blank and the forged barrel. The tangential and axial flow stresses of the barrel blank and the forged barrel are also presented.
基金Project(51105287)supported by the National Natural Science Foundation of ChinaProject(2012BAA08003)supported by the Key Research and Development Project of New Products and New Technologies of Hubei Province,ChinaProject(2013M531750)supported by China Postdoctoral Science Foundation
文摘Cold rotary forging is an advanced and complex metal forming technology with continuous local plastic deformation.Investigating the contact force between the dies and the workpiece has a great significance to improve the life of the dies in cold rotary forging.The purpose of this work is to reveal the contact force responses in cold rotary forging through the modelling and simulation.For this purpose,a 3D elastic-plastic dynamic explicit FE model of cold rotary forging is developed using the FE code ABAQUS/Explicit.Through the modelling and simulation,the distribution and evolution of the contact force in cold rotary forging is investigated in detail.The experiment has been conducted and the validity of the 3D FE model of cold rotary forging has been verified.The results show that: 1) The contact force distribution is complex and exhibits an obvious non-uniform characteristic in the radial and circumferential directions; 2) The maximum contact force between the upper die and the workpiece is much larger than that between the lower die and the workpiece; 3) The contact force evolution history is periodic and every period experiences three different stages; 4) The total normal contact force is much larger than the total shear contact force at any given time.
基金Project(51105287)supported by the National Natural Science Foundation of ChinaProject(IRT13087)supported by Innovative Research Team Development Program of Ministry of Education of China+2 种基金Project(2012-86)supported by High-End Talent Leading Program of Hubei Province,ChinaProject(2014CFB876)supported by Natural Science Foundation of Hubei ProvinceChina
文摘Cold orbital forging is an advanced spur bevel gear forming technology. Generally, the spur bevel gear in the cold orbital forging process is formed by two steps: the preforming step and the final step. Due to the great importance of the final step to gear forming and its complication with interactive factors, this work aims at examining the influence of key factors on the final step in cold orbital forging of a spur bevel gear. Using the finite element(FE) method and control variate method, the influence rules of four key factors, rotation velocity of the upper tool, n, feeding velocity of the lower tool, v, tilted angle of the upper tool, γ, friction factor between the tools and the billet, m, on the geometry and the deformation inhomogeneity of the cold orbital forged gear are thoroughly clarified. The research results show that the flash becomes more homogeneous with increasing v, increasing m, decreasing n or decreasing γ. And the deformation of the gear becomes more homogeneous with increasing v, decreasing n or decreasing γ. Finally, a corresponding experiment is conducted, which verifies the accuracy of FE simulation conclusions.
基金financially supported by the National Natural Science Foundation of China(no.U21A20131)the Innovative Research Team Development Program of Ministry of Education of China(no.IRT17R83)for the support given to this research.
文摘Al5A06 sheets by large cold plastic deformation usually have high strength but low plasticity,i.e.weak strength-plasticity matching,which may lead to their poor fatigue property.In this study,annealing treat-ments are applied on cold rotary forged Al5A06 sheets to regulate strength-plasticity matching and im-prove fatigue properties.The microstructures,tensile mechanical properties and fatigue properties un-der different annealing parameters were analyzed.The abnormal grain growth mechanism of cold rotary forged Al5A06 sheets during 300℃ annealing treatment was investigated,and the fatigue failure mech-anism of Al5A06 sheets with different annealing temperatures was also investigated.The abnormal grain growth during 300℃ annealing treatment is mainly due to the asynchronous recrystallization behavior with low recrystallization driving force,which leads to the early recrystallized regions directly absorb-ing adjacent grains along134crystal direction.The cold rotary forged Al5A06 sheets after 250℃-2 h annealing treatment exhibit the best fatigue property,which is mainly because the optimum strength-plasticity matching brings about coordinate plastic deformation throughout most grains,and the effective dislocation movement between adjacent grains can delay the appearance of strain localization and ac-commodate continuous fatigue cyclic loading.
基金Project(51105287)supported by the National Natural Science Foundation of ChinaProject(2013M531750)supported by China Postdoctoral Science Foundation
文摘Cold closed-die forging is a suitable process to produce spur-bevel gears due to its advantages, such as saving materials and time, reducing costs, increasing die life and improving the quality of the product. The homogeneity of microstructure of cold closed-die forged gears can highly affect their service performance. The homogeneity of microstructure and Vickers hardness in cold closed-die forged gear of 20 Cr Mn Ti alloy is comprehensively studied by using optical microscopy and Vickers hardness tester. The results show that the distribution homogeneity of the aspect ratio of grain and Vickers hardness is the same. In the circumferential direction of the gear tooth, the distribution of the aspect ratio of grain and Vickers hardness is inhomogeneous and they gradually decrease from the surface to the center of the tooth. In the radial direction, the distribution of the aspect ratio of grain and Vickers hardness is inhomogeneous on the surface of the gear tooth; while it is relatively homogeneous in the center of the gear tooth. In the axial direction of the gear tooth, the distribution of the aspect ratio of grain and Vickers hardness is relatively homogeneous from the small-end to the large-end of the gear tooth.
文摘The chemical compositions and microstructures of the armor strips excavated from the Emperor Qin Shi Huang's mausoleum were examined systematically by using optical microscopy and electron microscopy.It was found that the armor strips were made of pure copper.Based on the morphology of α-Cu recrystal grain and copper sulphide(Cu2S) inclusions in the armor strips,the manufacturing techniques were proposed as follows:smelting pure copper,casting a lamellar plate,forming the cast ingots into sheets through repeated cold forging combined with annealing heat treatment,and finally cutting the sheets into filaments.Furthermore,through the deformation of copper sulphide(Cu2S) inclusions in the strips,the work rate during forging was evaluated and calculated to be close to 75%.
