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The International Journal of Advanced Manufacturing Technology

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20-08-2022 | ORIGINAL ARTICLE

Investigation of new method of large ingots forging based on upsetting of workpieces with ledges

Authors: Oleg E. Markov, Anton S. Khvashchynskyi, Anton V. Musorin, Marina A. Markova, Alexander A. Shapoval, Natalia S. Hrudkina

Published in: The International Journal of Advanced Manufacturing Technology | Issue 3-4/2022

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Abstract

A new method of upsetting the workpieces with conical ledges has been proposed and investigated in the paper. A workpiece’s relative height before upsetting was H/D = 3.0. Stress–strain state (SSS) has been investigated to determine the level and sign of the compressive stresses in the workpiece. Moreover, the parameter of the stress state in the place location of the axial defects has been evaluated. The degree of axial defect closing and a convexity value has been determined. These parameters have been determined for different dimensions of diameters and heights. It has been established that an upsetting workpiece with conical ledges leads to a uniform strain distribution into the workpiece body. During upsetting on the lateral surface and in the axial zone, there are compressive stresses due to the appearance of a concave workpiece shape. Moreover, there is a decreasing dimension of the axial defects and convexity lateral surface. Effective workpiece geometrical parameters have been determined. Relative diameter (d/D) and height (h/D) of the ledges should be equal from 0.5 to 0.7 and from 0.4 to 0.6, respectively. Recommended degree of upsetting is 50%. Determined recommendations have been verified experimentally during forging ingot with 66,500 kg weight. Obtained experimental data confirmed the results of finite element method (FEM) modeling. The investigation results have been implemented in the industry.

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Title: Investigation of new method of large ingots forging based on upsetting of workpieces with ledges
Authors: Oleg E. Markov
Anton S. Khvashchynskyi
Anton V. Musorin
Marina A. Markova
Alexander A. Shapoval
Natalia S. Hrudkina
Publication date: 20-08-2022
Publisher: Springer London
Published in: The International Journal of Advanced Manufacturing Technology / Issue 3-4/2022
Print ISSN: 0268-3768
Electronic ISSN: 1433-3015
DOI: https://doi.org/10.1007/s00170-022-09989-1

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