November 2023 Volume 5

FORGING RESEARCH

Digital Twin for Metal Forging Colorado School of Mines Industry Partners: Tkach Metal Forming Consultants & Queen City Forging The goal of this project is to determine the feasibility of using open source software to create a digital twin of metal forging that would optimize targeted physical quantities of interest. As a case study, we will aim to develop an elemental digital twin system to control temperature and its spatial distribution in components during room and elevated temperature forging. If successful, the proof-of concept will represent a stepping-stone for the development of more advanced digital twins capable of real-time optimization of forging/ forming operations to prevent undesired, localized microstructural changes. Fabrication of Forging Preforms by Additive Manufacturing Methods Cleveland State University Industry Partner: Canton Drop Forge The goal of this project is to fabricate forging preforms by additive manufacturing methods. Such preforms will allow one-step forging to finished shape/size instead of two or three steps. This approach can lead to significant savings in tooling costs, especially for short runs. Wire-arc Additive Manufacturing for Forging Dies Georgia Southern University Industry Partners: COR-MET & McKees Rocks Forgings The goal of this project is to fabricate forging dies with wire arc additive manufacturing (WAAM). In order to achieve this goal, the proposed project has the following objectives: State of the art literature review, cost analysis, selection of alloys for wire-arc additive manufacturing, design of dies for WAAM, evaluation of the mechanical properties and characterization of the microstructure of wire-arc additively manufactured forging die alloys. The wire fabricated by our industry partner COR-MET will be used for the wire-arc additive manufacturing process. Improvements of H13 Forging Tool Life Through TiC Reinforced Inconel 6 Lehigh University Industry Partners: American Axle & Manufacturing & Scientific Forming Technologies The goal of this project is to increase the life of hot forging tooling by applying TiC reinforced Inconel 625 coating via the selective laser melting process on the H-13 tool steel. The manufactured coupons under various processing conditions will be analyzed for the best mechanical and tribological performance. The best SLM condition will be selected to fabricate compression samples to be used to establish the flow stress material model as a function of temperature, strain, and strain rate. This model will be available for FEM numerical simulation of the hot forging process using DEFORM 3D in the next stage of the project.

Predicting Site-Specific Microtexture During Forging of Ti-6Al-4V

University of Florida Industry Partner: ATI

The goal of this project is to develop a computationally inexpensive framework capable of predicting the site-specific evolution of microtexture in titanium alloy forgings. Manufacturing Automation Cell (MAC) Project The goal of this Manufacturing Automation Cell (MAC) project is to serve as a catalyst and advance the field of manufacturing education. This project aims to increase the number of qualified advanced manufacturing technicians by working collaboratively with industry partners to develop work-based learning opportunities. The project will take a multilayered approach through innovative training methods, real world hands-on projects and lab-based manufacturing opportunities. This will enable educators and practitioners to more effectively develop critically needed skilled workers in one of the most rapidly growing sectors of manufacturing. Intensive Quenching of Die Steels: Compressive Stresses The University of Akron Industry Partner: Viking Forge The goal of this project is to advance the state of the art in quench processing of high carbon high-alloy tool and die steels. Advanced tool steels are of interest to forgers because the life of the punch or die is critical when forging components. Failures in dies occur due to fatigue (mechanical and thermal), deformation, cracking, chipping and erosion. We aim to study heat treatment of common tool steels used in the forging industry to improve die life through improved surface properties through introduction of beneficial stresses. Predicting The Occurrence of Central Burst During Open Die Forging of High Strength Steels Université du Québec Industry Partners: Transvalor & Finkl Steel The goal of this project is to quantify the impact of various open die forging parameters on the occurrence of centerline burst during open die forging of large size forgings. This will be achieved through a combination of finite element modeling using the FEM code FORGE NXT4, and experimental work using a Gleeble 3800 thermomechanical simulator and its MaxStrain module that is specially designed for simulating the forging process, as well as, the 1000 tons instrumented hot forging press. Blackhawk Technical College Industry Partner: Scot Forge

FIA MAGAZINE | NOVEMBER 2023 78