August 2019 Volume 1

FORGING RESEARCH

6.1.1. Progressive Forging Sequence for Hollow Layshafts with Flanges at the End....................................................................82 6.1.2. Progressive Forging Sequence for Hollow Layshafts with Flanges at the Middle..............................................................83 6.2. FEModeling for Hollow Layshafts.............................................................................................................................................84 6.2.1. FEModeling for Hollow Layshafts with Flanges at the End.............................................................................................84 6.2.2. FEModeling for Hollow Layshafts with Flanges at the Middle ......................................................................................91 6.3. FE Simulation Results for Hollow Layshafts...............................................................................................................................97 6.3.1. FE Simulation Results for Hollow Layshafts with Flanges at the End...............................................................................97 6.3.2. FE Simulation Results for Hollow Layshafts with Flanges at the Middle.........................................................................100 6.4. Concluding Remarks..................................................................................................................................................................103\ Chapter 7..................................................................................................................................................................................................104 Development of Laboratory Scale Test Setup for Differential Heating Based Forging Process for Hollow Shafts.....................................104 7.1. Metal Flow Pattern and Process Feasibility in Lab-scale Experiments.........................................................................................104 7.1.1. FEModeling of the Proposed Process for Lab-scale Experiments......................................................................................105 7.1.2. Process Feasibility of the Proposed Process for Lab-scale Testing......................................................................................107 7.2. Selection of an Induction Heater for the Lab-scale experiments..................................................................................................109 7.3. Design of a Lab-scale Tooling......................................................................................................................................................111 7.4. Experimental Setup.....................................................................................................................................................................114 7.5. Experimental Results...................................................................................................................................................................117 7.6. Concluding Remarks..................................................................................................................................................................119 Chapter 8..................................................................................................................................................................................................120 Development of Proposed Process for Field Trials.....................................................................................................................................120 8.1. Progressive Forging Sequence of the Proposed Process andThree Types of Die Configuration...................................................120 8.2. Metal Flow Pattern and Process Feasibility for Field Trials.........................................................................................................121 8.2.1. FEModeling of the Proposed Process for the Field Trial. .................................................................................................121 8.2.2. Process Feasibility of the Proposed Process for Field Trial................................................................................................124 8.3. Mitigation of the Strain Concentration in the Product...............................................................................................................127 8.4. Concluding Remarks..................................................................................................................................................................129 Chapter 9..................................................................................................................................................................................................130 Conclusions. .............................................................................................................................................................................................130 Acknowledgment......................................................................................................................................................................................132 References.................................................................................................................................................................................................132 Appendix I Induction Heating Design......................................................................................................................................................136 I.I Definition, application and advantage of Induction Heating........................................................................................................136 I.II Design of the Induction Heating by Analytical Calculation........................................................................................................137 I.III FEModeling..............................................................................................................................................................................144 I.III.I FEModeling of the Eddy Current Analysis.............................................................................................................................144 I.III.II FEModeling of the Transient Thermal Analysis. ...................................................................................................................148 I.IV FE Simulation Results for Induction Heating............................................................................................................................150

FIA MAGAZINE | August 2019 50