November 2020 Volume 2

FORGING RESEARCH AND TECHNOLOGY

6. Conclusion 1. Lazorkin-Engineering Company has developed four main types of FDFD, which can be used for forging ingots and workpieces of any form and to obtain all types of forgings. 2. The design schemes of three FDFD types during forging process ensure that additional intensive shear deformations are applied in the transverse plane of an ingot/workpiece, which helps to obtain a high quality of a metal. One type of FDFD is similar to RFM by the how the dies interact with a workpiece. However, this FDFD type, opposed to RFM and to the other types of FDFD, allows one to decrease the forces during forging by 20-40% and, therefore, can be applied during the forging of the workpieces made from steels and alloys with high deformation resistance using forging presses with low power. 3. All four types of FDFD can be equipped with newly developed systems for fixing the dies as well as with systems to fix FDFD to the movable press cross-beam and to a working table of a press. The time required for fixing and changing the dies and the time required to fix FDFD to the movable press cross-beam and to a working table of a press was decreased significantly in comparison to the previously used systems. 4. All types of forging devices differ from each other and have their own technological features. However, they have common technological features, which allows them to be used as versatile devices for obtaining forgings with round cross-sections, for example. 5. Many actual examples of industrial applications of the Four Die Forging Devices confirm their high efficiency. 6. The industrial application of FDFDs is characterized by the worldwide geography of their application and by a wide range of forces of the forging presses where these devices are installed. References 1. V.A. Lazorkin, D. V. Lazorkin: Technologies, machines and devices for forging between four dies , translation from Russian by L. V. Karnushkina. Zaporozhye: STATUS, 2019. 2. Lazorkin V., Lazorkin D., Onischenko R., Kuralekh S: Analysis of two-die and four-die forging processes implemented on hydraulic forging presses and RFM, Proc. 20th IFM 2017, Sept. 15-19, Congress Graz, Austria, pp. 535-544. ■ Viktor Lazorkin Technical Director Lazorkin-Engineering, LLC Lazorkin.engineering@gmail.com Sergey Kuralekh Representative in EU Countries

After dimension values of an ingot (workpiece), a pass number and angle of workpiece rotation around its longitudinal axis are given in brackets. The forging was performed from the beginning and until the 19th pass (inclusive) using two flat dies. The workpiece was re-heated after the 9th pass back to the forging temperature range. During the 16th to 19th passes, the workpiece was swaged along its ribs to make its form polygonal before the consequent calibration. Then, after the 20th pass, a calibration was performed using two contoured dies. Beginning from the 1st and until the 22nd pass, the turning of the workpiece was performed by an angle, which value is provided in brackets after the dimensions of the workpiece. During the 23rd to the 25th passes, the workpiece was turned by an angle of 45°, 40°, or 35° after every single reduction and feed of the workpiece. The feeds of the workpiece during the 1st through 22nd passes were 200-260 mm. During the 23rd and the 24th passes, they were 50 mm, and at the 25th pass, the feed was 35 mm. After installation of the FDFD, which had been designed by Lazorkin-Engineering Company, into this forging press, the same 9Cr1Mo ingots were forged during ten or nine passes using the different forging schedules ( See Forging Schedules Nos. 2 and 3 below. Forging Schedule No. 2: Ingot with Ø600 mm (1,45°) → 560 mm (2,45°) → … → 250 mm (10,20°) → Ø250 mm. Forging Schedule No. 3: Ingot of 532 x 532 mm size (1,45°) → 500 mm (2,45°) → … → 250 mm (9,20°) → Ø250 mm. The productivity of the forging with the application of FDFD in comparison with two dies forging increased 2.5-2.7 times and the quality of the metal was improved as well. Furthermore, the processing cycle for the production of forgings has shrunk significantly and the additional re-heating of workpieces was eliminated. Forging devices developed by our company have found their industrial application not only at forging presses but also in radial forging machines of our own design [1]. Several RFMs with our FDFDs were working for many years without any failures in the company, which specializes in the production of special products made from high alloyed steels, alloys, and nonferrous metals. The first FDFD was designed by Dr. Viktor Lazorkin in 1990 for a 5MN forging press. After this, and to the present day, 29-off FDFDs have been manufactured for metallurgical and machine-building companies in ten countries worldwide. This number also includes three forging devices, manufactured for RFMs with forces of 1,25 MN and 1,6 MN. 26 other devices have been manufactured for the forging presses with forces from 5 to 120MN. FDFDs of our design are mostly used with the 20-25MN forging presses (11 FDFDs), less often with the 30-35 MN forging presses (6 FDFDs). The design solutions of our Four-Die Forging Devices and forging technologies for them are patented in ten countries.

Lazorkin-Engineering, LLC Sergey.Kuralekh@yahoo.com

FIA MAGAZINE | NOVEMBER 2020 116