Theoretical and Experimental Damage Prediction in Cold and Semi‐Hot Bulk Forming of Ductile Steels

Bulk forging is among the most important manufacturing methods in metal forming, due to its wide applicability from some ounces to several tons of steel in a high diversity of shapes and forming conditions. Economical constraints demand for further optimisation and cost‐effective production. This requires the application of suitable finite elements simulation software, in order to support the already digitalised construction processes. Ductile damage is one of the most severe problems to arise during the production sequences, not only in cold but also in semi‐hot forging operations. Mathematical approaches exist for the modelling and simulation of ductile fracture in steel. In this paper some widespread used damage models are introduced and discussed. Their damage prediction quality has been verified by experiments, the tensile test and the collar specimen upsetting with several different steels under cold and semi‐hot forging conditions. The methods for the experimental fracture detection are introduced as well. In cold forging the passive ultrasonic testing with integrated statistical filtering algorithms is used. As this method is not applicable to semi‐hot forging experiments, optical fracture detection by means of a high‐speed camera is used instead. A very interesting material behaviour of the steels tested has been identified in the semi‐hot upsetting of collar specimen. For every steel a distinct temperature crossover interval exists, in which the forging process abruptly changes from damaged to undamaged state. This interval amounts to some degrees Celsius only for each of the seven materials investigated. Among the damage models proposed, the Model of Effective Stresses by Lemaitre is chosen for the application to a cold and a semi‐hot forging operation. These industrial processes of an axle end (cold) and a journal bearing (semi‐hot) are susceptible to damage for reasons to be discussed in this paper. It will be shown that the internal fracture of the axle end (chevrons) and the surface fissures of the journal bearing can be predicted with high accuracy. Moreover, the application of the damage model in the finite element software MSC.SuperForm 2004 offers a promising approach for process optimisation. Several possibilities could be tested for their suitability of reducing the calculated damage: geometry variation of the forming tools, process annealing, different materials. The use of damage models in finite element simulation can be regarded as a further step towards an optimal process design.     

Deposition welding of hot forging dies using nanoparticle reinforced weld metal

In the application field of forging, the form-giving tool components are subject to process-related severe environmental conditions, such as high mechanical loads acting simultaneously with high tribological and thermal charges. Due to high machine hour rates as well as increasing environmental requirements in terms of energy consumption, wear protection methods and suitable repair measures for forging tools become more and more important. Laser deposition welding represents an established process for the repair of complex shaped surfaces. A new approach is the addition of nano-sized ceramic particles to improve the mechanical properties. The main idea is to reduce the grain size of the cladded layers by adding nano-sized nuclei. A fine grained microstructure will improve strength as well as ductility and fatigue resistance. Furthermore small hard particles can improve the wear resistance without affecting the friction of the surface. After the cladding process the surface has to be finished usually by turning, milling and grinding operations. Within the presented paper the potential of nanoparticle-reinforced deposition welding with regard to increasing the wear resistance of forging dies will be examined. First, the process of nanoparticle-reinforced deposition welding will be presented. Afterwards it will be shown that yttrium oxide, titanium carbide and tungsten carbide nanoparticles in an AISI H10 matrix material will influence the friction coefficient between forging tool and material as well as the wear properties.     

Ermittlung von Verfahrensgrenzen für das Fügen durch Knickbauchen anhand des Werkstoffes E235+N

Through a systematic approach and the consistent comparison of the results between experimental and numerical investigations, a deep understanding of the bulging mechanisms has been first developed. From these investigations process limitations were derived and presented in the form of a working diagram for the material E235+N. With regard to a wide industrial use of upset bulging as a joining technology, a technologically, productively as well as economically appropriate method could be developed and validated by means of practical and numerical experiments.     

Development of an innovative monitoring system for spray fields in hot forging processes

In the field of forging the production processes are subject to extreme influences. This leads to failures in process steps or part qualities. To guarantee a high product quality and process stability it is necessary to measure and evaluate the process parameters during the manufacturing process. Online monitoring systems are especially required to avoid high scrap costs. In this paper an innovative concept for monitoring the spray field of massive forming processes is presented. So far a practical method to monitor the lubrication process for purpose of quality assurance and process fault diagnosis in forging processes does not exist. With the sensor system developed at the Institute of Forming Technology and Machines a qualitative and quantitative assessment of spray fields used for cooling and lubrication of forging die processes is possible. The sensor system operates on the basis of current flow measurements and is able to realize a local determination of the spray field. Furthermore an artificial neuronal network (ANN) was programmed to collect, evaluate and analyze the signal of the sensors automatically. Such networks have already been proven to detect and analyze process failures. Especially in the analyses of systems depending on many parameters and their interactions with each other ANN offer the advantage to deliver the desired statements on the basis of suitable test series.     

Investigations of ductile damage during the process chains of toothed functional components manufactured by sheet-bulk metal forming

Sheet-bulk metal forming processes combine conventional sheet forming processes with bulk forming of sheet semi-finished parts. In these processes the sheets undergo complex forming histories. Due to in- and out-of-plane material flow and large accumulated plastic strains, the conventional failure prediction methods for sheet metal forming such as forming limit curve fall short. As a remedy, damage models can be applied to model damage evolution during those processes. In this study, damage evolution during the production of two different toothed components from DC04 steel is investigated. In both setups, a deep drawn cup is upset to form a circumferential gearing. However, the two final products have different dimensions and forming histories. Due to combined deep drawing and upsetting processes, the material flow on the cup walls is three-dimensional and non-proportional. In this study, the numerical and experimental investigations for those parts are presented and compared. Damage evolution in the process chains is simulated with a Lemaitre damage criterion. Microstructural analysis by scanning electron microscopy is performed in the regions with high mechanical loading. It is observed that the evolution of voids in terms of void volume fraction is strongly dependent on the deformation path. The comparison of simulation results with microstructural data shows that the void volume fraction decreases in the upsetting stage after an initial increase in the drawing stage. Moreover, the concurrent numerical and microstructural analysis provides evidence that the void volume fraction decreases during compression in sheet-bulk metal forming.     

Fertigung einer universellen Hüftprothesenpfanne mittels Hochdruckblechumformung

In recent years, the use of hip prostheses has become a routine procedure. The use of total hip replacement has evolved in recent years to a routine procedure. Despite this experience, it always comes back to complications. Especially the migration or loosening of the acetabular component because of the artificial load adaptive bone remodeling is still a current problem. This is due to the changing mechanical situation after the implantation of the prosthesis. Another problem is the high bone loss during implantation, which complicates a revision of the prosthesis. One solution is the use of patient‐specific prostheses. So far, the use of these prostheses is limited due to the time‐consuming and cost‐intensive production. The overall objective of the presented project in this publication is the development and establishment of an innovative concept for the production of patient‐specific hip prosthesis made of titanium plates by sheet metal forming. The idea of this concept involves the development of a two‐stage process. First of all a standardized hip prosthesis is made by high‐pressure sheet metal forming and then individually in the second step. This publication contains the derivation of the standard prosthesis. For this purpose, a design methodology was generated, based on the so‐called agglomerative clustering. In addition, presents the results of the numerical preliminary design of the first stage of the process and the tool developed concept in the course of this paper.     

Sanierung eines PCE-Schadens in einem makroskopisch oxischen Grundwasserleiter durch Stimulation anaerober dehalogenierender Bakterien

Grundwasser - Eine erfolgreiche biologische In-situ-Sanierung von PCE-kontaminierten Grundwasserleitern erfordert hinreichend reduzierende Bedingungen sowie die Anwesenheit von molekularem...     

Activity,selectivity, and methanol tolerance of novel carbon-supported Pt and Pt<Subscript>3</Subscript>Me (Me = Ni,Co) cathode catalysts

The activity, selectivity, and methanol tolerance of novel, carbon supported high-metal loading (40 wt.%) Pt/C and Pt₃Me/C (Me = Ni, Co) catalysts for the O₂ reduction reaction (ORR) were evaluated in model studies under defined mass transport and diffusion conditions, by rotating (ring) disk and by differential electrochemical mass spectrometry. The catalysts were synthesized by the organometallic route, via deposition of pre-formed Pt and Pt₃Me pre-cursors followed by their decomposition into metal nanoparticles. Characteristic properties such as particle sizes, particle composition and phase formation, and active surface area, were determined by transmission electron microscopy, energy dispersive X-ray spectroscopy, X-ray photoelectron spectroscopy, and X-ray diffraction. For comparison, commercial Pt/C catalysts (20 and 40 wt.%, E-Tek, Somerset, NJ, USA) were investigated as well, allowing to evaluate Pt loading effects and, by comparison with the pre-cursor-based catalyst with their much smaller particle sizes (1.7 nm diameter), also particle size effects. Kinetic parameters for the ORR were evaluated; the ORR activities of the bimetallic catalysts and of the synthesized Pt/C catalyst were comparable and similar to that of the high-loading commercial Pt/C catalyst; at typical cathode operation potentials H₂O₂ formation is negligible for the synthesized catalysts. Due to their lower methanol oxidation activity the bimetallic catalysts show an improved methanol tolerance compared to the commercial Pt/C catalysts. The results indicate that the use of very small particle sizes is a possible way to achieve reasonably good ORR activities at an improved methanol tolerance at DMFC cathode relevant conditions.     

Nanostructured supported palladium catalysts—Non-oxidative methane coupling

The Pd on α-Al₂O₃ catalysts with Pd particles in the low nanometer range have been prepared by a sonochemical reduction and a colloidal method, respectively. The two catalysts differ in their particle size, the widths of their particle size distributions and the amount of carbon incorporation in the Pd lattice.The adsorptive properties of the Pd/Al₂O₃ samples are different as a result of the different preparation methods. The methane adsorption capacity of that sample with smaller particles is lower than that of the catalyst with larger particles and the energy of activation is nearly doubled. DRIFTS and TPD results of CO adsorption supported by transmission electron microscopy data indicate that the PdSON catalyst with smaller and more homogeneous particles than PdCOL is highly dispersed which influences the coupling-hydrogenolysis process.The catalytic activity evidenced the formation of different adspecies during methane coupling and chemisorption on both catalysts. During the hydrogenation the carbon adspecies formed mainly methane at low adsorption temperatures. The significant amount of adsorbed methane at 773 K is governed by the highly active coordination unsaturated sites at the surface.