November 2024 Volume 6

FORGING RESEARCH

Metamorphic Manufacturing Colorado School of Mines Industry Partner: Queen City Forging

Benchmarking Ergonomic Issues in the Forging Industry

Cleveland State University Industry Partner: SIFCO

The goal of this project is to show that Metamorphic Manufacturing (MM) is a potential pathway for the production of low-volume, performance-critical components. To do this, we will show that incremental deformation pathways enable unprecedented geometry and microstructure control, which are inaccessible to traditional deformation methods. The use of incremental forging results in previously unexamined deformation pathways, which means we have less understanding of microstructure and property evolution as a function of processing. These smaller, localized deformation increments, however, result in great opportunity to create desired microstructures at various locations within a component. If we can better understand microstructure evolution during complex imposed deformation sequences, we will not only make custom component geometries, but will also design those components to have improved performance. Preform Design for Flash-less Die Forging The goal of this study is to develop preform design schemes for flash less die forging featuring 2D (axisymmetric and plane strain) and 3D problems. The schemes will be developed for use in conjunction with point tracking function in DEFORM 2D and 3D software packages. The mapping schemes are expected to contain algorithms for data transformation between DEFORM simulations and a CAD program. Non-Metallic Inclusion Evolution During Vacuum Processing of Steel Carnegie Mellon University Industry Partner: Universal Stainless The goal of this project is to study the changes that occur to non metallic inclusions during vacuum induction melting (VIM) and vacuum arc remelting (VAR). Previous work has shown large inclusions containing elements such as Ca, Al, and Si can become entrained in VAR ingots. The VAR process can effectively remove small non-metallic inclusions, but large (100s of micrometers diam eter) can persist in the melt pool and become entrained in the solid. Investigation of Decarburization of Steel on Forgings North Carolina State University Industry Partner: Cornell Forge

The goal of this project is to benchmark injury risk within the forging industry by reviewing safety statistics provided by the Forging Industry Association, reviewing safety data provided by SIFCO, conducting on-site assessments of individuals who have sustained an injury of the upper extremity, collecting biomechanical data (kine matics and kinetics) pertaining to a task that has been associated with repetitive movement disorders, and then creating a biomechanical model of the upper extremity to ascertain muscle and joint loads during the task being analyzed. This model will be matched to the gender and size of the most commonly injured worker. The overall goal of this exercise is to determine baseline conditions for a common injury, with the long-term objective of either modifying the task or the tool(s) used. 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 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 addi tive 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. Manufacturing Methods Cleveland State University Industry Partner: Canton Drop Forge

Cleveland State University Industry Partner: SIFCO

The goal of this project is to study and characterize decarburized layer of oxidized steel samples provided by SIFCO industries. This analysis will help to select proper surface engineering treatment in order to prevent decarburization during preheating of forging billet.

FIA MAGAZINE | NOVEMBER 2024 63