Bulk metal formed parts for power plants Peças forjadas ... · Peças forjadas para plantas de...

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


Wind turbine with forged rings and shafts



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



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




1 2 5



3 4 6


Results: microstructure simulation




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



equations

FEM

PEP/LARSTRAN


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



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




1 2



3 4


Results: geometry



Lf = 320 mm Bf = 25 mm Hf = 20 mm


Results: microstructure simulation




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



equations

FEM

PEP/LARSTRAN


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



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



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%)


EXPERIMENTAL PROCEDURE - FIRST STEP: PIERCING




EXPERIMENTAL PROCEDURE - SECOND STEP: COGGING




DETAILED SEQUENCE OF COGGING PROCESSE




SIMULATION - FIRST STEP: PIERCING




RESULTS - FIRST STEP: PIERCING




RESULTS - SECOND STEP: COGGING




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



equations

FEM

PEP/LARSTRAN


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



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



Initial Billet

Deformed Billet

Water Quenching

analyzed region

METALLOGRAPHY


RESULTS: Simulation and Experimental (900oC)

A B



C A – Probe heated and

quenched (grain size ≈ 50 µm)

B – Probe heated forged and


C – Simulation of case B (grain

size ≈ 25 to 29 µm)



A B



C A – Probe heated and quenched

(grain size ≈ 100 µm)



C – Simulation of case B (grain size ≈

45 to 52 µm)



A B



C A – Probe heated and




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



Forging of long parts: first step – effective strain

Forging of long parts: seconda step – effective strain

http://www.ufrgs.br/ldtm/pesquisa/bragecrim/Forging of compact parts first step.html

http://www.ufrgs.br/ldtm/pesquisa/bragecrim/Forging of compact parts second step.html

http://www.ufrgs.br/ldtm/pesquisa/bragecrim/Forging of long parts first step.html

http://www.ufrgs.br/ldtm/pesquisa/bragecrim/Forging of long parts seconda step.html

http://www.ufrgs.br/ldtm/pesquisa/bragecrim/Forging of long parts first step st.html

http://www.ufrgs.br/ldtm/pesquisa/bragecrim/Forging of long parts seconda step st.html

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



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.



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