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Bragecrim Meeting
Berlin, October, 2010
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Laboratório de Transformação Mecânica (Metal Forming)
Universidade Federal do Rio Grande do Sul, BRAZIL
Prof. Dr. Ing. Lirio Schaeffer
Peças forjadas para plantas de energia
Wind turbine with forged rings and shafts
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Bulk metal formed parts for
power plants
Preliminary
experiments
(parts ≈ 1,0 kg)
Preliminary
experiments
(parts ≈ 20,0 kg)
Material
data
Simulation
Phenomenological
equations
Compression test
V = constant
Forging of
compact parts
Research flowchart
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
equations
FEM
PEP/LARSTRAN
11/2010Simufact.Forming
V = constant
Compression test
= constant
01/2011
Forging of
long parts
Forging of
long hollow parts
Next steps
Bulk metal formed parts for
power plants
Preliminary
experiments
(parts ≈ 1,0 kg)
Preliminary
experiments
(parts ≈ 20,0 kg)
Material
data
Simulation
Phenomenological
equations
Compression test
V = constant
Forging of
compact parts
Research flowchart
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
equations
FEM
PEP/LARSTRAN
11/2010Simufact.Forming
V = constant
Compression test
= constant
01/2011
Forging of
long parts
Forging of
long hollow parts
Next steps
Preliminary experiments (parts ≈ 1,0 kg)/Simulation - forging of compact parts
Goals: search the fundamentals of hot open die forging, check microstructural changes
that occur during the forging process and compare experimental and numerically
simulated results.
Experimental Procedure:
Material: ABNT 4140
H0 = 75 mm
D0 = 44 mm
υο = 1000 oC
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Preliminary experiments (parts ≈ 1,0 kg)/Simulation - forging of compact parts
1 2 5
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
3 4 6
Preliminary experiments (parts ≈ 1,0 kg)/Simulation - forging of compact parts
Results: microstructure simulation
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Bulk metal formed parts for
power plants
Preliminary
experiments
(parts ≈ 1,0 kg)
Preliminary
experiments
(parts ≈ 20,0 kg)
Material
data
Simulation
Phenomenological
equations
Compression test
V = constant
Forging of
compact parts
Research flowchart
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
equations
FEM
PEP/LARSTRAN
11/2010Simufact.Forming
V = constant
Compression test
= constant
01/2011
Forging of
long parts
Forging of
long hollow parts
Next steps
Preliminary experiments (parts ≈ 1,0 kg)/Simulation - forging of long parts
Goals: search the fundamentals of hot open die forging, check microstructural changes
that occur during the forging process and compare experimental and numerically
simulated results.
Experimental Procedure: Material: ABNT 4140
First step: L0 = 200 mm D0 = 32 mm Hf = 20 mm SB = 65mm υο = 1000 oC
Second step: Hf = 25 mm SB = 65mm υο = 1000 oC
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Preliminary experiments (parts ≈ 1,0 kg)/Simulation - forging of long parts
1 2
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
3 4
Preliminary experiments (parts ≈ 1,0 kg)/Simulation - forging of long parts
Results: geometry
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Lf = 320 mm Bf = 25 mm Hf = 20 mm
Preliminary experiments (parts ≈ 1,0 kg)/Simulation - forging of long parts
Results: microstructure simulation
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Bulk metal formed parts for
power plants
Preliminary
experiments
(parts ≈ 1,0 kg)
Preliminary
experiments
(parts ≈ 20,0 kg)
Material
data
Simulation
Phenomenological
equations
Compression test
V = constant
Forging of
compact parts
Research flowchart
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
equations
FEM
PEP/LARSTRAN
11/2010Simufact.Forming
V = constant
Compression test
= constant
01/2011
Forging of
long parts
Forging of
long hollow parts
Next steps
Preliminary experiments (parts ≈ 1,0 kg)/Simulation - forging of long hollow parts
Goals: search the fundamentals of hot open die forging, check microstructural changes
that occur during the forging process and compare experimental and numerically
simulated results.
Experimental Procedure: Material: ABNT 4140
First step: piercing
Billet dimensions: D0 = 60 mm Ho = 60 mm
Initial temperature: υο = 1200 oC
Hole diameter: d = 10 mm
Die speed: V = 4 mm/s
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Die speed: V = 4 mm/s
Mass loss by piercing: 15 %
Second step: cogging
Reheating temperature: υ = 1200 oC
Fixed stroke: Δh = 10 mm
End diameter: Df = 50.4 mm (reduction: 16%)
Final length: Lf = 75 mm (elongation: 25%)
Preliminary experiments (parts ≈ 1,0 kg)/Simulation - forging of long hollow parts
EXPERIMENTAL PROCEDURE - FIRST STEP: PIERCING
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Preliminary experiments (parts ≈ 1,0 kg)/Simulation - forging of long hollow parts
EXPERIMENTAL PROCEDURE - SECOND STEP: COGGING
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Preliminary experiments (parts ≈ 1,0 kg)/Simulation - forging of long hollow parts
DETAILED SEQUENCE OF COGGING PROCESSE
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Preliminary experiments (parts ≈ 1,0 kg)/Simulation - forging of long hollow parts
SIMULATION - FIRST STEP: PIERCING
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Preliminary experiments (parts ≈ 1,0 kg)/Simulation - forging of long hollow parts
RESULTS - FIRST STEP: PIERCING
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Preliminary experiments (parts ≈ 1,0 kg)/Simulation - forging of long hollow parts
RESULTS - SECOND STEP: COGGING
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Bulk metal formed parts for
power plants
Preliminary
experiments
(parts ≈ 1,0 kg)
Preliminary
experiments
(parts ≈ 20,0 kg)
Material
data
Simulation
Phenomenological
equations
Compression test
V = constant
Forging of
compact parts
Research flowchart
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
equations
FEM
PEP/LARSTRAN
11/2010Simufact.Forming
V = constant
Compression test
= constant
01/2011
Forging of
long parts
Forging of
long hollow parts
Next steps
Phenomenological equations
DYNAMIC RECRYSTALLISATION STATIC RECRYSTALLISATION AND GRAIN GROWTH
⋅⋅ε=
TR
QexpZ W&
32 aa
01peak Zda ⋅⋅=ε
43 ee
02peak1stat Zdee ⋅⋅+ε⋅=ε
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
ε−ε
ε−ε⋅−=
2d
kritstat
krit1dyn dexp1X
2f
maxf31 )kfsinh(fZ ⋅⋅=
( )( )( )3C
21 ZlnCexp1CC ⋅−⋅=
Material data/Simulation - microstructural transformations in hot forming
Goals: search microstructural changes that occur during the hot forging process and compare
experimental and numerically simulated results.
Experimental Procedure:Material: ABNT 4140
H0 = 50 mm
D0 = 35 mm
υο = 900, 1100, 1200 oC
ε = 0.5
V = 3.7 mm/s
Press Assembly
Furnace Heated Billet
METALLOGRAPHY
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Initial Billet
Deformed Billet
Water Quenching
analyzed region
METALLOGRAPHY
Material data/Simulation - microstructural transformations in hot forming
RESULTS: Simulation and Experimental (900oC)
A B
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
C A – Probe heated and
quenched (grain size ≈ 50 µm)
B – Probe heated forged and
quenched (grain size ≈ 30 µm)
C – Simulation of case B (grain
size ≈ 25 to 29 µm)
Material data/Simulation - microstructural transformations in hot forming
RESULTS: Simulation and Experimental (1100oC)
A B
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
C A – Probe heated and quenched
(grain size ≈ 100 µm)
B – Probe heated forged and
quenched (grain size ≈ 50 µm)
C – Simulation of case B (grain size ≈
45 to 52 µm)
Material data/Simulation - microstructural transformations in hot forming
RESULTS: Simulation and Experimental (1200oC)
A B
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
C A – Probe heated and
quenched (grain size ≈ 100 µm)
B – Probe heated forged and
quenched (grain size ≈ 50 µm)
C – Simulation of case B (grain
size ≈ 45 to 50 µm)
Simulation videos
Forging of compact parts: first step – temperature
Forging of compact parts: second step – temperature
Forging of long parts: first step – temperature
Forging of long parts: seconda step – temperature
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Forging of long parts: first step – effective strain
Forging of long parts: seconda step – effective strain
BRAGECRIM TEAM AT LdTM/UFRGS AND CREDITS IN THIS PRESENTATION
Prof. Dr. Ing. Lirio Schaeffer – General coordination
Dr. Eng. Alberto Moreira Guerreiro Brito – Simulation, planning and coordination of experiments,
study of the phenomenological equations to microstructural modelling and final edition of this
presentation.
Enga Daiana M. Margutti – Preliminary experiments (parts ≈ 1,0 kg) - forging of compact parts.
Enga Christiane Rosado – Preliminary experiments (parts ≈ 1,0 kg) - forging of long parts.
Eng. Gianpaulo Alves Medeiros – Preliminary experiments (parts ≈ 1,0 kg) - forging of long hollow
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
Eng. Gianpaulo Alves Medeiros – Preliminary experiments (parts ≈ 1,0 kg) - forging of long hollow
parts; Material data - microstructural transformations in hot forming.
Eng. M.Sc. Alexsandro S. Moraes – Simulations with Simufact.Forming.
Est. Diego Lovatel Zollner – Metallography and general support to experiments.
ACKNOWLEDGEMENTS
We want to thank the „Coordenação de Aperfeiçoamento de Pessoal de
Nível Superior “ and the „ Conselho Nacional de Desenvolvimento Científico
e Tecnológico“ for the financial support.
Bulk metal formed parts for power plants
Peças forjadas para plantas de energia
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