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Analysis of the production process of the forked forging used in the excavator drive system in order to improve the currently implemented technology by the use of numerical modeling

Marek Hawryluk
Marek Hawryluk
, 
Marcin Rychlik
Marcin Rychlik
, 
Jacek Ziemba
Jacek Ziemba
, 
Katarzyna Jasiak
Katarzyna Jasiak
, 
Filip Lewandowski
Filip Lewandowski
 y 
Łukasz Dudkiewicz
Łukasz Dudkiewicz
   | 13 oct 2021
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Publicado en línea: 13 oct 2021
Páginas: 227 - 239
Recibido: 22 jun 2021
Aceptado: 01 sept 2021
DOI: https://doi.org/10.2478/msp-2021-0020
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© 2021 Marek Hawryluk et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Fig. 1

View of (A) a ‘hot’ forging with the flash after the forging process, (B) a cooling forging after trimming, and (C) a CAD model of a forging after mechanical treatment.
View of (A) a ‘hot’ forging with the flash after the forging process, (B) a cooling forging after trimming, and (C) a CAD model of a forging after mechanical treatment.

Fig. 2

Images of the consecutive operations of forming a yoke-type forging and the corresponding analysis of the temperature distributions made with a thermovision camera: (A) upsetting during open die forging; (B) finishing forging; (C) hot trimming; and (D) calibration.
Images of the consecutive operations of forming a yoke-type forging and the corresponding analysis of the temperature distributions made with a thermovision camera: (A) upsetting during open die forging; (B) finishing forging; (C) hot trimming; and (D) calibration.

Fig. 3

Other selected stages of the process which can affect the correctness of the whole technology: (A) transport of the forging from open forging to die forging; (B) lower die for roughening and finishing forging during a maintenance shutdown; and (C) container with hot forgings after hot calibration.
Other selected stages of the process which can affect the correctness of the whole technology: (A) transport of the forging from open forging to die forging; (B) lower die for roughening and finishing forging during a maintenance shutdown; and (C) container with hot forgings after hot calibration.

Fig. 4

3D scanning analysis of the geometrical changes of forgings in the actual forging process.
3D scanning analysis of the geometrical changes of forgings in the actual forging process.

Fig. 5

View of the impression's filling: (A) open forging operations; (B) forging in the roughing pass (placing the preform, after the second blow, and after the last blow); (C) forging in the finishing impression (after the first and the last blows); and (D) model of a ready forging with flash.
View of the impression's filling: (A) open forging operations; (B) forging in the roughing pass (placing the preform, after the second blow, and after the last blow); (C) forging in the finishing impression (after the first and the last blows); and (D) model of a ready forging with flash.

Fig. 6

Distributions of plastic deformations after forging: (A) after flattening of the tip and leveling; (B) after roughing; and (C) after finishing forging.
Distributions of plastic deformations after forging: (A) after flattening of the tip and leveling; (B) after roughing; and (C) after finishing forging.

Fig. 7

Numerical simulation results: (A) temperature distributions; (B) mean stress distributions; (C) reduced stress distributions on lower dies during roughing; and (D–F) parameters analyzed for finishing forging.
Numerical simulation results: (A) temperature distributions; (B) mean stress distributions; (C) reduced stress distributions on lower dies during roughing; and (D–F) parameters analyzed for finishing forging.

Fig. 8

Defects on the forgings observed after the forging process: (A) laps revealed after mechanical treatment between the arms in the parting plane; (B) underfills observed after shoot blasting; and (C) cuts and wraps after trimming and blasting.
Defects on the forgings observed after the forging process: (A) laps revealed after mechanical treatment between the arms in the parting plane; (B) underfills observed after shoot blasting; and (C) cuts and wraps after trimming and blasting.

Fig. 9

The most common forging defects and exemplary results of forging defect detection obtained from FEM, using the “folds” function (laps): (A) visible laps on the arms and in the shank during preliminary die forging; (B) wrong arrangement in the die (too high) – laps on the arms, (C) too strong flattening of the tip (laps on the corners and in the mandrel). FEM, finite element method.
The most common forging defects and exemplary results of forging defect detection obtained from FEM, using the “folds” function (laps): (A) visible laps on the arms and in the shank during preliminary die forging; (B) wrong arrangement in the die (too high) – laps on the arms, (C) too strong flattening of the tip (laps on the corners and in the mandrel). FEM, finite element method.

Fig. 10

Filling of the impression of a yoke forging made in a prolonged working cycle: (A) results presenting the tool-forging contact, pointing to an underfill at the beginning of the arms; (B) temperature distributions for a cooled forging during an increased number of blows; (C) temperature distributions for a forging made according to the improved technology.
Filling of the impression of a yoke forging made in a prolonged working cycle: (A) results presenting the tool-forging contact, pointing to an underfill at the beginning of the arms; (B) temperature distributions for a cooled forging during an increased number of blows; (C) temperature distributions for a forging made according to the improved technology.

Fig. 11

Forging force courses for particular operations in the function of distance to close of dies.
Forging force courses for particular operations in the function of distance to close of dies.

Fig. 12

Temperature distribution on the material in initial forging: (A) after upsetting; (B) after flattening the end and leveling; (C) after initial forging (after four strokes); and (D) after finishing forging (after two strokes).
Temperature distribution on the material in initial forging: (A) after upsetting; (B) after flattening the end and leveling; (C) after initial forging (after four strokes); and (D) after finishing forging (after two strokes).

Fig. 13

Comparison of the produced 1,000th forgings after improvements and changes resulting from FEM. FEM, finite element method.
Comparison of the produced 1,000th forgings after improvements and changes resulting from FEM. FEM, finite element method.
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