May 2019 Volume 1

FORGING RESEARCH

2. EXPERIMENTAL SETUPANDMETHODOLOGY.............................................................................................................................14 2.1 Hydraulic Press Setup.....................................................................................................................................................................14 2.2 Die Set....................................................................................................................................................................................................20 2.2.1 PlatenDesign and Fabrication. .....................................................................................................................................21 2.2.1.1Machining Procedure toAchieve LowSurface Roughness .............................................................24 2.2.1.2Machining Procedure toAchieveHigh Surface Roughness.............................................................24 2.2.2 Instrumentation...................................................................................................................................................................25 2.3 WorkpieceMaterial andGeometry...........................................................................................................................................29 2.3.1 AluminumWorkpiece and Preparation.....................................................................................................................29 2.3.2 Steel Workpiece and Preparation...............................................................................................................................31 2.4 Experimental Methodologies......................................................................................................................................................33 2.4.1 Lubrication.............................................................................................................................................................................34 2.4.2 Ring Test.................................................................................................................................................................................35 2.4.3 Cigar Test.............................................................................................................................................................................. 40 3. RESULTSANDDISCUSSION..................................................................................................................................................................45 3.1 Ring Test Results andDiscussion...............................................................................................................................................45 3.1.1 Ring Test GeometricChanges andAnalysis............................................................................................................46 3.1.2 Ring Test Friction Factor Trends andAnalysis........................................................................................................47 3.1.3 Ring Test Friction Factor andAnalysis for Aluminum..........................................................................................52 3.1.4 Ring Test Friction Factor Trends andAnalysis for Steel.....................................................................................59 3.1.5 Ring Test Compression of Aluminumand Steel Conclusions.........................................................................65 3.2 Cigar Test Results andDiscussion............................................................................................................................................67 3.2.1 Cigar Test Results of Aluminum....................................................................................................................................67 3.2.2 Cigar Test Results of Steel..............................................................................................................................................72 3.3 Spread Ratio and True Strains.................................................................................................................................................... 80 3.3.1 AluminumTrue Strains..................................................................................................................................................... 80 3.3.2 Steel True Strains................................................................................................................................................................86 3.3.3 AluminumSpread Ratios.................................................................................................................................................91 3.3.4 Steel Spread Ratios...........................................................................................................................................................94 4. SUMMARYANDCONCLUSIONS..........................................................................................................................................................97 5. BIBLIOGRAPHY......................................................................................................................................................................................... 101 6. APPENDICES..............................................................................................................................................................................................104 6.1 Ring Test.............................................................................................................................................................................................104 6.2 Cigar Test............................................................................................................................................................................................115 6.3 Strain................................................................................................................................................................................................... 122 6.4 Spread Ratio..................................................................................................................................................................................... 135

FIA MAGAZINE | MAY 2019 39