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Procedia Engineering 81 (2014) 480 485
11th International Conference on Technology of Plasticity, ICTP 2014, 19-24 October 2014,
Nagoya Congress Center, Nagoya, Japan
Research & Department Section, Technical Development Department, Steel Casting & Forging Division, KOBE STEEL, LTD., 2-3-1,
Shinhama, Arai-cho, Takasago-city, Hyogo, 676-8670, Japan
b
Turbo Machinery Engineering SectionRotating Machinery Engineering DepartmentCompressor Division, KOBE STEEL, LTD., 2-3-1,
Shinhama, Arai-cho, Takasago-city, Hyogo, 676-8670, Japan
c
Mechanical Working Research Section Material Research Laboratory, KOBE STEEL, LTD., 1-5-5, Takatsukadai, Nishi-ku,Kobe, Hyogo, 6512271, Japan
Abstract
In hot free forging process of large products, surface cracks occur occasionally. When these cracks occur, they must be
removed by hot scarfingprocess after stopping forging process temporarily. Final products have no cracks on those surfaces
after applying the hot scarfing process. Hot scarfing process, however, cuts into productivity due to additional time consuming.
Since surface cracks are regarded as significant defects, suppression of the surface crack generation is important issue. A lot of
research has been studied about mechanism and criteria of forging crack generation [1]~[8]. In hot forging process, however,
there are a few researches [9]~[14]. Then the mechanism and criteria of crack generationduring the hot forging process are not
clear at this moment. There are various factors for crack generation, such as reduction ratio, forging temperature, anvil shape,
ingot surfaceintegrity and so on. The goal of this research is to clarify the mechanism of crack generation in actual forging
processes. The derived mechanism is applied to design anvil shapes by using numerical forging simulation.
2014 Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
2014 The Authors. Published by Elsevier Ltd.
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection
University
and Toyohashi
University
of Technology.
Selection and
and peer-review
peer-review under
under responsibility
responsibility of
of Nagoya
the Department
of Materials
Science
and Engineering,
Nagoya University
Keywords: Hot forging; Foging defect; Surface crack; Surface defect; Anvil shape
1877-7058 2014 Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer-review under responsibility of the Department of Materials Science and Engineering, Nagoya University
doi:10.1016/j.proeng.2014.10.026
1. Introduction
In hot free forging process of large products, surface cracks occur occasionally. When these cracks occur, they
must be removed by hot scarfingprocess after stopping forging process temporarily. Final products have no cracks
on those surfaces after applying the hot scarfing process. Hot scarfing process, however, cuts into productivity due
to additional time consuming. Since surface cracks are regarded as significant defects, suppression of the surface
crack generation is important issue. The mechanism and criteria of crack generationduring the hot forging process
are not clear at this moment. There are various factors for crack generation, such as reduction ratio, forging
temperature, anvil shape, ingot surfaceintegrity and so on. The goal of this research is to clarify the mechanism
of crack generation in actual forging processes. The derived mechanism is applied to design anvil shapes by using
numerical forging simulation.
2. Investigation ofactual forging process
The target actual forging process is the cogging processwhich forms a round bar from a steel ingot. One of the
mechanism hypotheses of surface cracks generationis illustrated in Fig. 1. In the cogging process, minor defect
was generated on the surface that has been forged. It was observed to occur at anvil lap part during cogging
process. When tensile stress is applied to minor defect during forging operation, it is expected that a crack will be
generated from the minor defect which is regarded as a stress concentration point. It is important to prevent minor
defect generation on the surface.
481
482
Si
Mn
Cr
0.45
0.25
0.80
0.15
Anvil
Width =30mm
Edge radius= R2.5
100mm
90mm
90mm
Heating
(Temparature 1250)
Test billet
Forging
(Reduction ratio:23%)
The cross-sectional shape and metal flow of billet obtained from the experiment are shown in Fig. 4. It shows
minor defect was occurred at anvil lap part. Since minor defect area had metal flow, it was suggested the
possibility of preventing minor defect generation by metal flow control.
(a)
(b)
Minor defect
1mm
(c)
2000
Fig. 4.DForged billet, (b) cross-sectional shape and (c) metal flow of billet obtained from experiment.
In order to confirm deformation behavior of forged surface, simulation is applied to the cogging process using
FE analysis (FORGETR). The cross-sectional shape of billet obtained from FE analysis under the same conditions
with the experiment of Fig. 4 are illustrated in Fig. 5. The calculated result is good agreement with experiment one.
The deforming behavior of forged surface obtained from FE analysis is shown in Fig. 6. It shows that the minor
defect was formed at anvil lap part by material flow with stroke during forging.
483
(b)
(a)
Minor defect
Fig. 5. (a) Forged billet and (b) cross-sectional shape of billet obtained from FE analysis.
Anvil lap part
(a)
(b)
Anvil
(c)
Minor defect
Forged area
Billet
Fig. 6. Deforming behavior of forged surface obtained from FE analysis: (a) stroke=0 mm; (b) stroke=15 mm;(c) stroke=30 mm.
Hf
V max .
dH
V
eq
(1)
where max is the maximum principle stress, eq is the equivalent stress andf is the equivalent strain.
The C-value contours during cogging process obtained from FE analysis is shown in Fig. 8. Maximum C-value
is generated at minor defect parts. It shows crack generation is easy to occur at minor defect part. The result was
suggested suppression of minor defect leads to prevent surface crack generation.
(a)
Anvil
(b)
1000
750
Billet
500
Fig. 7. Analysis model: (a) illustration of billet model and anvil model; (b) initial temperature distribution.
484
0.2
0.0
Fig. 8. C-value contours during cogging process obtained from FE analysis.
100
160
200
150, 300
300
150, 150
25
20
15
R100
10
R160
R200
R300
0
0
50
Reduction /mm
Fig. 9. (a) Definition of minor defect depth and (b) relationship between reduction and minor defect depth.
485
Anvil
Height direction
h
a
Billet
25
20
15
10
5
0
Axial direction
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Aspect ratio
Fig. 10. (a) Definition of aspect ratioand (b) relationship between aspect ratio and minor defect depth.
6. Conclusion
Possibility of surface crack generation in cogging process was evaluated by Cockcroft and Latham ductile
fracture evaluation parameter (C-value) obtained from FE analysis. Maximum C-value is generated at minor defect
parts. The result shows crack generation is easy to occur at minor defect part and it was suggested suppression of
minor defect leads to prevent surface crack generation. As a result of investigation minor defect generation in
cogging process, it was generated at anvil lap part of forged surface. In addition, it was found the minor defect
depth correlate with the edge shape of anvil. In order to minimize surface crack generation, the anvil edge shape
which can minimize aspect ratio is effective.
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