Advanced disk-forging process in producing heavy defect-free disk using counteracting dies
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ORIGINAL RESEARCH
Advanced disk-forging process in producing heavy defect-free disk using counteracting dies Namyong Kim 1 & Il Yeong Oh 2 & Sang Wook Han 2 & Ji Hoon Kim 2 & Chester J. VanTyne 3 & Young Hoon Moon 2 Received: 5 June 2020 / Accepted: 21 October 2020 # Springer-Verlag France SAS, part of Springer Nature 2020
Abstract During the conventional disk-forging, the upper die repeatedly compresses materials on the flat stationary base. As the strain distributions of the forged disk are non-uniform owing to friction and uneven temperature distribution, more uniform deformation within the entire volume is desirable to obtain sound disk free from defects. This study proposes an advanced disk-forging process in the production of a defect-free heavy disk using counteracting dies. An industry-applicable disk-manufacturing process using a conventional single die-forging process and a proposed counteracting die were characterized and compared based on variations in geometries with successive forging steps. Variations in stress, equivalent strain, and temperature were obtained through three-dimensional finite element simulations using FORGE™ software, during the disk-forging processes of cylindrical preforms. Comparison of the simulation results indicated that the proposed forging process using counteracting dies was highly effective in producing sound disks having uniform microstructure without process-induced defects. The shop-floor production was performed to validate the proposed process, and the feasibility of the process was demonstrated based on the forged disk qualities that were assessed by non-destructive examination and mechanical testing. The test data showed that the defect-free disk with uniform mechanical properties was successfully produced through the proposed forging process using counteracting dies. Keywords Heavy disk . Disk forging . Counteracting die . Incremental forming . Finite element method
Introduction Heavy forged disks are commonly used for vital parts of equipment in power generation, heat exchanger, and chemical containers to save material, energy, and production steps [1–3]. The forming of the disk-shaped products is carried out by forging by mainly upsetting it between an upper and lower die. This upsetting process compresses the cast dendritic microstructure and internal voids in the ingot, which gives strength and toughness that is difficult to obtain using other
* Young Hoon Moon [email protected] 1
Research and Development Center, Taewoong Co., Ltd, Noksansandan 27-ro, Gangseo-gu, Busan 46751, Republic of Korea
2
School of Mechanical Engineering, Pusan National University, Busandaehak-ro 63, Geumjeong-gu, Busan 46241, Republic of Korea
3
Department of Metallurgical and Materials Engineering, Colorado School of Mines, Golden, CO 80401, USA
metal-forming processes [4–9]. Forged disks are superior in quality to disks cut from plates or bars due to the microstructural refining effect induced during forging operations. Furthermore, forged disks can be forged with grain flow
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