Angela Selau Marques

Optimizing Hot Forging Process Parameters of Hollow Parts Using Tubular and Cylindrical Workpiece: Numerical Analysis and Experimental Validation

CAE (computer aided engineering) evaluates the forging process virtually to optimize the industrial production. The numerical and experimental investigations of forging process of a hollow part are important in industrial point of view. This study has been focused on the development of a 3D elastic-plastic FEM (finite element model) of hot forging to evaluate the forming process of hollow parts. The validity of this method was verified through a laboratory experiment using aluminum alloy (AA6351) with medium geometric complexity. The distributions of effective strain, temperature, metal flow and strength were analyzed for two different initial workpieces (tubular and cylindrical). It was observed that both initial workpieces can be used to produce the final hollow part using the numerical simulation model. The results showed that the numerical analyses predict, filling cavity, calculated strength, work temperature and material flow were in agreement with the experimental results. However, some problems such as air trapping in the die causing incomplete filling could not be predicted and this problem was resolved experimentally by drilling small holes for air release in the dies.

Analysis of Forging Dies Coated with Tungsten Carbide through HVOF Processing

In this paper we present a performance evaluation of thermal spraying coated hot forging dies conducted in a production line. The High Velocity Oxy-Fuel process was used for the deposition of a tungsten carbide coating, which is characterized by its optimal adherence and low porosity. A metallurgical characterization of the layer was previously done, in order to obtain reference information to assist in the interpretation of the practical tests results. The coated die allowed an increase in productivity of 37.5%, besides better dimensional stability results through the process and legibility of printed numbers.