The near netshape manufacturing of affordable titanium components for. Predictions of maximum forging load and effective stress for strainhardening material of near net shape helical gear fea, abductive network variation of material parameters like yielding stress, strength coefficient and strain hardening exponent deform 3d helical gear optimum forging load, effective stress zhu et al. Precision forging concept is a costeffective way to produce netshape or nearnet shape components. Other applications will have different cost ratios. In figure 1 the final product of 285q is presented. Casting, forming, and forging gear solutions magazine. Research on the near net shape hollow forging technology. Near net shape forging leads to saving in material, processing cost and finishing cost. Near net shape is an industrial manufacturing technique. Custom manufacturer of metal forgings including near net shape forgings. Casting, forming, and forging gear manufacture depends on machinery available, design speci. The name implies that the initial production of the item is very close to the final net shape, reducing the need for surface finishing. Pdf near net shape spur gear forging using concave preform. Gear teeth for automotive gearboxes cannot yet be forged to.
In the past various researches have worked on net shape forging by using simulation technique suc guoqun zhao et. Depending on the temperature employed, near net shape. Taylan altan, professor and director, and mayur deshpande erc for net shape forming, the ohio state university. Nearnet and net shape forging request pdf researchgate.
Hot hydroforging concept of net shape gear forging with teeth and the. Near net shape spur gear forging using concave preform. Request pdf nearnet and net shape forging precision forging is an innovative manufacturing process for the flashless, nearnet shape production of highperformance components. Actual values can be determined only by consultation with the forging company representative. There is a singlepart production or shortrun production at best.
Precision forging processes for highduty automotive. In precision forging operations, sometimes machining is fully eliminated which is called near net shape forging. The advantage for net shape forging over hand forging begins at 110 units. The method is adaptable for a range of shapes, from simple to the very complex. Near net shape manufacturing technologies produce components that are close to the finished size and shape, requiring a minimal amount of finishing process such as machining. The near net shape forged steel gears with light weight core can enable an. Request pdf nearnet and net shape forging precision forging is an innovative manufacturing process for the flashless, nearnet shape production of. The term nearnet shape forging indicates that some but not all of the forging. Sort by date 1 manufacturing net shaped, coldformed gears. Aluminum is a common material that can be cold forged depending on final shape.
Net shape forgings are forged to net and near net shapes with many functional surfaces forged to required tolerances, requiring no machining. Metal forming processes indian institute of technology. Precision forging enables manufacture of forgings with enhanced geometrical and dimensional accuracy, such as net shape or near net shape components, in large quantities and with reasonable cost. This working process may take place in one stage or several stages. Isothermal nearnet shape forging of aluminum alloys. Sales of the most of them vary during long periods. The increased flytobuy ratios that can be achieved by netshape manufacturing can alleviate supply problems whilst still applying pressure to reduce component. The introduction of near net shape forming technologies in bearing industry has led to significant savings in material, time, energy. A near net shape nns ringrolling process was developed to reduce the forging weight of a rolled, fan case front, ring made of ti6al4v. The evolution of nearnetshape ringrolling processes for. Near net shapeforging of titanium alloy turbine blade. Some examples of shapes obtained by forging process. Near net shape technologies have expanded these concepts, targeting mainly primary shaping process, such as casting or forging. Near net shape manufacturing of new, low cost titanium.
Forging is a manufacturing method in which compressive forces are used to shape a metal slug into a nearnet shape product with the use of a tool. About 30% of the material is wasted during conventional closeddie forging. A forging process was also developed for the manufacturing of preforms with a complex. Only of a small part of forgings, we can say that the interest in them is stable. Crane hook, connecting rod of ic engine, spanner, gear blanks etc. Modeling of the heating sequences of lightweight steelaluminum bimaterial billets for hot forging and hot hydroforging. Little or no waste some operations are near net shape or net shape processes. Overview and design of near netformed spherical involute.
This innovative development results in stronger components and the improvement of the performance of the engine. Near netshape forging with fem internship at skoda 1. In manufacturing discrete parts by forming or other near net shape manufacturing processes. Most forgings are intended for external customers in machined and unmachined states. Design for forming and other near net shape manufacturing. Near net shape forgings often require tight radii and narrow features to be filled, necessitating particularly high forging loads. Near net shape refers to processes that produce parts requiring little or no machining to complete. For simple example, forging a gear with teeth requires higher loads than forging the same cylindrical enclosing geometry. Modeling of the heating sequences of lightweight steel. The desired outcomes of manufacturability analysis for nearnetshape nns processes are cost and leadtime reduction through minimization of process steps in. Although forging has the function of forming complicated crosssectional shapes, conventional forging from bars is inappropriate to the production of cups having comparative large thickness and plates having complicated. A near net shape forging can be either one in which some but not all of the surfaces are net or one in which the surfaces require only minimal machining or.
The elimination of flash also helps to increase the strength of the product as defects cropping up due to trimming of the flash are eliminated. National science foundation and for a consortium of companies. For that reason, several procedures based on the application of near and net shape forming technologies such as forging, extrusion and rolling have been developed. Precision forging an overview sciencedirect topics. Near net shapeforging of titanium alloy turbine blade aklyasu moritashlgeo hattorikazuhrto tani1 atsushl takemura2and yoshlo ashida2 mechanical engineering research laboratory, kobesteel. Forging for production of gear blanks and precisionforged near and netshape gears.
It is one of the oldest metalworking arts with its origin about some thousands of years back. An overview of forging processes with their defects. Pdf near net shape spur gear forging using concave. Development of inconel alloy ma 6000 turbine blades for.
The process normally refers to two types of forging, cold and warm. Article information, pdf download for near net shape manufacturing of. Reducing traditional finishing such as machining or grinding eliminates more than twothirds of the production costs in some industries. This product is a driving wheel of the third speed gear. Design and selection of the right grade melting heat treatment premachining non destructive testing machining to net shape remelting powder atomization. Forging is a metal working process in which useful shape is obtained in solid state by hammering or pressing metal. Therefore, in order to reduce the cost of forged products and to obtain nearnet or net shape parts, new forging methods should be applied. Sustainable solutions for aerospace high integrity components. Near net shape forging is most common when parts are forged without heating the slug, bar or billet. In addition, content from the 1988 edition has been split into a twovolume set.
This volume focuses on bulkworking operations that include primary operations, in which cast products or consolidated powder billets are worked into mill shapes such as bar, plate, tube, sheet, wire, and. Forging technology is at the stage where bevel gears may be formed to net shape. A net shaped metal forming process has been developed for manufacturing quality, durable, highyield and costefficient gears for highvolume production. The process normally refers to two types of forging. This was achieved by optimizing the ringrolling process in which metallurgical and geometrical process was improved. Spur and helical gears of certain envelope geometries may be cold formed to high accuracies. Forging andor rolling forging andor closeddie forging. Jain allison gas turbine division of general motors corporation indianapolis, indiana abstract this paper deals with allisons work with the ma 6000 alloy aimed at near net shape forgings and thermal protection coatings for uncooled turbine.
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