Optimization of the forming of special alloys products

Development of a forging and rolling technology for
nickel-based alloys. Small and large crankshaft forging
technologies will be optimized using numerical simulation

Special requirements on material properties in various branches of industry, such as creep characteristics, corrosion-resistance, wear-resistance, yield strength - breaking strength ratio, fatigue properties, etc., make it necessary to utilise new types of ferrous and non-ferrous alloys. The forming of these alloys is very often problematical due to difficult formability and insufficient knowledge of optimal forming conditions. Detailed formability testing is then necessary, in order to determine right forming parameters. Numerical simulation of forming should keep optimal conditions in all parts of the formed body. The high costs of special alloys and the required quality and reliability demand mathematical modelling of several forming technology alternatives and careful results analysis. Due to the variety of technologies required, 2D and 3D modelling of both viscoplastic and elastoplastic material is necessary. Three types of materials and technologies were chosen as very relevant: NiMoCr alloy as a high creep strength material with excellent corrosive properties is being developed for the new production programmes of SKODA A.S. The development and production of NiMoCr alloy semi-finished products is provided by SKODA VYZKUM cooperating with SKODA STEEL and KOVOHUTE ROKYCANY. Applications for the utilization of this alloy lie mainly in energetics and the chemical industry. Forging of an ingot and following hot rolling resulting in NiMoCr strips are subjects for Fine Element Method (FEM) simulation of material processing. Formability tests results and recrystallisation diagrams will be analysed before numerical modelling - in order to obtain input data for the simulation programme. The simulation of both sample testing and real technological processing will then be provided. After finding a suitable technology, real products will be produced. Small crankshafts for the automotive industry are produced from micro-alloyed steel by drop forging technology at the SKODA STEEL company. These products are destined for the SKODA MLADA BOLESLAV company for FELICIA cars. The FEM simulation of the forming process should optimise shapes of forming dies, prices of material input, the number of forming operations and the quality of the output material. Large crankshafts for ship engines are also produced at the SKODA STEEL company. These components, almost 10 metres long weighing about 30 tons, are produced by hammer forging on a big hydraulic press. This unique production technology should provide the complicated shape of this production, sufficient screening of all parts of the piece, providing the right structure and satisfactory properties of the material and an acceptable value of residual elastic stress. The minimalization of the weight of input semi- finished products and a minimalization of the time and energy consumption will be solved in the proposed project. Keywords: simulation, forming, heat treatment.
Project ID: 
1 869
Start date: 
Project Duration: 
Project costs: 
870 000.00€
Technological Area: 
Market Area: 

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.