Experimental investigation of a variable flash gap regarding material flow and influence of trigger forces
Experimental investigation of a variable flash gap regarding material flow and influence of trigger forces
复制标题
关于材料流动和触发力影响的可变闪光间隙的实验研究
DOI：
10.1007/s11740-015-0611-1
复制
发表时间：
2015
期刊：
影响因子：
--
通讯作者：
Behrens
中科院分区：
文献类型：
--
作者：
Langner;Stonis;Behrens
飞边闭式模锻是批量成形工艺中最常见的方法。这些工艺的一个主要特性是使用剩余材料来确保完全填充锻模的型腔。多余的材料通过闪边被排出模具。毛边焊盘的设计对模具的填充有重大影响。通常，飞边区域的尺寸在模具制造过程中是固定的，并且在锻造过程中不能改变。需要额外的加工操作来适应例如不同的工艺参数或发生模具磨损，从而恶化型腔的填充。通过使用在锻造过程中可以主动改变的可变且可移动的溢边间隙，可以将更多的材料保持在型腔中，从而允许改善型腔的填充。另外，这样的系统可用于适应过程中变化的过程参数。本文将描述可变闪隙的研究。确定了这种系统对模腔填充的影响。这是通过与具有固定飞边区域的传统锻造工艺进行比较来完成的。此外，还研究了可变溢料间隙的不同触发力，这对成型操作期间的材料流动也有影响。最后，将实验结果与FEA模拟结果进行比较。实验表明，可变的闪边间隙对材料流动有明显的影响。闪光比越高，可变闪光间隙的影响就越大。传统锻造零件与可变飞边间隙锻造零件之间的零件高度差异为 4.6 毫米，相当于 17.2%。不同的触发力也会对零件的高度产生影响。触发力越高，可变闪光间隙的影响越大。一般来说，结果与 FEA 模拟的预测相符。实验表明，可变的溢边间隙能够改善型腔的填充。该方法可以更轻松地适应不同的工艺参数，无需额外的加工操作，从而提高锻造零件的质量。
Closed die forging with flash is the most common method of bulk forming processes. One main property of these processes is the use of a surplus material to ensure a complete filling of the cavity of the forging die. The surplus material is driven out of the die through the flash land. The design of the flash land has a major influence on the filling of the die. Usually, the dimensions of the flash land are fixed during the manufacturing of the die and can’t be changed within the forging process. Additional machining operations are necessary to adapt to e.g. different process parameters or to occurring die wear which deteriorates the filling of the cavity. By use of a variable and moveable flash gap which can be actively changed during the forging process more material can be held in the cavity, thus permitting the improvement of the filling of the cavity. Additionally, such a system can be used to adapt to varying process parameters within the process. In this paper the investigation of a variable flash gap will be described. The influence of such a system on the filling of the die cavity is determined. This is done by comparison with a conventional forging process with a fixed flash land. Additionally, different trigger forces of the variable flash gap were investigated which also have an influence on the material flow during the forming operation. At last, the results of experimental trials are compared to results of FEA simulations. Experimental trials showed that the variable flash gap has a clear influence on the material flow. The higher the flash ratio, the bigger is the influence of the variable flash gap. Differences in height of the parts of 4.6 mm, which correspond to 17.2 %, were reached between a conventionally forged part and a part forged with a variable flash gap. Different trigger forces also have an influence on the height of the parts. The higher the trigger force, the bigger the influence of the variable flash gap. In general, the results match the predictions of FEA simulations. Experimental trials showed that a variable flash gap is able to improve the filling of the cavity. This method can be used to increase the quality of forging parts by a much easier adaption to different process parameters without additional machining operations.
DOI：
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发表时间：
2006
期刊：
影响因子：
--
作者：
Sang Kon Lee;Hyun Sang Byun;B. Kim;D. Ko;C. Kang
通讯作者：
C. Kang
DOI：
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发表时间：
2009
期刊：
Production Engineering
影响因子：
--
作者：
B. Behrens;R. Nickel;S. Müller
通讯作者：
S. Müller
闭式模锻件飞边设计规则的审查
DOI：
--
发表时间：
1992
期刊：
影响因子：
--
作者：
E. Sleeckx;J. Kruth
通讯作者：
J. Kruth