journal of materials processing technology · 2/1/2011  · open die forging of large cast ingots...

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Journal of Materials Processing Technology 211 (2011) 1136–1145 Contents lists available at ScienceDirect Journal of Materials Processing Technology journal homepage: www.elsevier.com/locate/jmatprotec Internal void closure during the forging of large cast ingots using a simulation approach Y.S. Lee a , S.U. Lee b , C.J. Van Tyne c , B.D. Joo d , Y.H. Moon d,a Dept. of Material Processing Division, KIMS, Changwon, Republic of Korea b Technical Center, POSCO Special Steel Co., Changwon, Republic of Korea c Dept. of Metallurgical and Materials Engineering, Colorado School of Mines, Golden, CO 80401, USA d School of Mechanical Engineering, Pusan National University, 30 Jangjeon-dong, Geumjeong-gu, Busan 609-735, Republic of Korea article info Article history: Received 30 July 2010 Received in revised form 17 January 2011 Accepted 22 January 2011 Available online 1 February 2011 Keywords: Cast ingot Open die forging Void closure FEM Effective strain abstract Large cast ingots often contain defects or undesirable microstructural features, such as voids and zones related to casting. Some of these features can remain after hot open die forging, which is an important process for converting large cast ingots into wrought components. During the initial cogging and deforma- tion steps prior to the detailed open-die-forging operations, any internal voids should be eliminated. The present work focuses on the closure of internal voids during open die forging so as to produce a sound com- ponent. Hot compression tests were conducted to obtain the flow strength of the cast microstructure at different temperatures and strain rates. The measured flow strength data together with other appropriate material properties were used to simulate the forging steps for a large cast ingot. The numerical simula- tions for the forging deformation and for the internal void behavior were performed using DEFORM-3D TM . Actual defects were measured in commercial ingots with an X-ray scanner. The simulation results for the void deformation behavior are compared with voids measured before and after forging. Through the comparison of experimental results and numerical simulation, a criterion for void closure is proposed. The criterion is that a local effective strain value of 0.6 or greater must be achieved for void closure during forging. Such a criterion can be used in conjunction with simulations to insure that a sound component is produced during the hot open die forging of large cast ingots. © 2011 Elsevier B.V. All rights reserved. 1. Introduction Recently, there is an increasing need to produce large forged components for aerospace, naval, energy, and other applications. Open die forging of large cast ingots is the primary process used to produce high quality large wrought components. Cogging or side-pressing processes are used in the primary stages during most open-die forgings. In this study we will use the industrial term “upsetting” for what is sometimes called side pressing in the lit- erature. Upsetting in the present study is not the compression of a cylinder along its axis, but rather the compression of a cylin- der perpendicular to the axis of symmetry. During the preliminary deformation processes, any internal voids from the initial cast ingot need to be eliminated. If these voids are not closed during the ini- tial deformation stages, they may nucleate a crack or be a source for a defect during the subsequent open die hot forging steps. Fig. 1 shows an example of an internal void and the surface crack that Corresponding author. Tel.: +82 51 5102372; fax: +82 51 5121722. E-mail address: [email protected] (Y.H. Moon). can result if the void was not closed during the initial cogging or upsetting operations. 1.1. Background A number of studies have been conducted on using finite ele- ment analysis to help with the operation and control of open die forging processes. Kiefer and Shah (1990) used three-dimensional FEM to examine the effects of die width and reduction on the inter- nal stresses and strains in an open die forging of rectangular shaped workpieces. Lee et al. (2008a,b) examined the effects of tempera- ture and strain rate on high temperature deformation behaviors to draw deformation processing map. Dudra and Im (1990a) used two-dimensional FEM to study the axial compression of a cylin- der and the plane-strain side pressing (i.e. upsetting) of a circular cross-sectioned workpiece by open die forging. The side-pressing study used dies of different configurations to investigate press loads and internal strains. Cho et al. (1998) also used three-dimensional FEM to study the effect of die configuration, die width and reduc- tion on the open die forging of rectangular billets. They evaluated their results by comparing the calculations to small sized laboratory 0924-0136/$ – see front matter © 2011 Elsevier B.V. All rights reserved. doi:10.1016/j.jmatprotec.2011.01.017

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Page 1: Journal of Materials Processing Technology · 2/1/2011  · Open die forging of large cast ingots is the primary process used to produce high quality large wrought components. Cogging

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Journal of Materials Processing Technology 211 (2011) 1136–1145

Contents lists available at ScienceDirect

Journal of Materials Processing Technology

journa l homepage: www.e lsev ier .com/ locate / jmatprotec

nternal void closure during the forging of large cast ingots using aimulation approach

.S. Leea, S.U. Leeb, C.J. Van Tynec, B.D. Jood, Y.H. Moond,∗

Dept. of Material Processing Division, KIMS, Changwon, Republic of KoreaTechnical Center, POSCO Special Steel Co., Changwon, Republic of KoreaDept. of Metallurgical and Materials Engineering, Colorado School of Mines, Golden, CO 80401, USASchool of Mechanical Engineering, Pusan National University, 30 Jangjeon-dong, Geumjeong-gu, Busan 609-735, Republic of Korea

r t i c l e i n f o

rticle history:eceived 30 July 2010eceived in revised form 17 January 2011ccepted 22 January 2011vailable online 1 February 2011

eywords:ast ingotpen die forging

a b s t r a c t

Large cast ingots often contain defects or undesirable microstructural features, such as voids and zonesrelated to casting. Some of these features can remain after hot open die forging, which is an importantprocess for converting large cast ingots into wrought components. During the initial cogging and deforma-tion steps prior to the detailed open-die-forging operations, any internal voids should be eliminated. Thepresent work focuses on the closure of internal voids during open die forging so as to produce a sound com-ponent. Hot compression tests were conducted to obtain the flow strength of the cast microstructure atdifferent temperatures and strain rates. The measured flow strength data together with other appropriatematerial properties were used to simulate the forging steps for a large cast ingot. The numerical simula-

TM

oid closureEMffective strain

tions for the forging deformation and for the internal void behavior were performed using DEFORM-3D .Actual defects were measured in commercial ingots with an X-ray scanner. The simulation results forthe void deformation behavior are compared with voids measured before and after forging. Through thecomparison of experimental results and numerical simulation, a criterion for void closure is proposed.The criterion is that a local effective strain value of 0.6 or greater must be achieved for void closure duringforging. Such a criterion can be used in conjunction with simulations to insure that a sound componentis produced during the hot open die forging of large cast ingots.

. Introduction

Recently, there is an increasing need to produce large forgedomponents for aerospace, naval, energy, and other applications.pen die forging of large cast ingots is the primary process used

o produce high quality large wrought components. Cogging oride-pressing processes are used in the primary stages during mostpen-die forgings. In this study we will use the industrial termupsetting” for what is sometimes called side pressing in the lit-rature. Upsetting in the present study is not the compression ofcylinder along its axis, but rather the compression of a cylin-

er perpendicular to the axis of symmetry. During the preliminaryeformation processes, any internal voids from the initial cast ingot

eed to be eliminated. If these voids are not closed during the ini-ial deformation stages, they may nucleate a crack or be a sourceor a defect during the subsequent open die hot forging steps. Fig. 1hows an example of an internal void and the surface crack that

∗ Corresponding author. Tel.: +82 51 5102372; fax: +82 51 5121722.E-mail address: [email protected] (Y.H. Moon).

924-0136/$ – see front matter © 2011 Elsevier B.V. All rights reserved.oi:10.1016/j.jmatprotec.2011.01.017

© 2011 Elsevier B.V. All rights reserved.

can result if the void was not closed during the initial cogging orupsetting operations.

1.1. Background

A number of studies have been conducted on using finite ele-ment analysis to help with the operation and control of open dieforging processes. Kiefer and Shah (1990) used three-dimensionalFEM to examine the effects of die width and reduction on the inter-nal stresses and strains in an open die forging of rectangular shapedworkpieces. Lee et al. (2008a,b) examined the effects of tempera-ture and strain rate on high temperature deformation behaviorsto draw deformation processing map. Dudra and Im (1990a) usedtwo-dimensional FEM to study the axial compression of a cylin-der and the plane-strain side pressing (i.e. upsetting) of a circularcross-sectioned workpiece by open die forging. The side-pressing

study used dies of different configurations to investigate press loadsand internal strains. Cho et al. (1998) also used three-dimensionalFEM to study the effect of die configuration, die width and reduc-tion on the open die forging of rectangular billets. They evaluatedtheir results by comparing the calculations to small sized laboratory
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Y.S. Lee et al. / Journal of Materials Processing Technology 211 (2011) 1136–1145 1137

part a

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cated that during the early stages void closure increases with thelevel of stress triaxiality increases. Their criterion for void closuredepends on the hydrostatic stress, the effective stress, the effectivestrain, the Norton exponent (essentially the inverse of the strain

Fig. 1. Surface crack of forged

xperiments using plasticine model materials at a scale of 1–40.amura and Tajima (2001) used three-dimensional FEM to studyhe formation of a surface deformation pattern that they calledconcave defect”. They verified their results by laboratory exper-ments using lead as a model material. From their analysis theylso provided a recommendation for a small die modification tovoid the surface defect. Tamura and Tajima (2003) and Tamurand Tajima (2004) extended their work to develop a pass scheduleor open die forgings, which provides a more homogeneous strainistribution within the workpiece. Tamura et al. (2005) furtherxtended their studies of open die forging to determine a die shapehat would minimize overlap defects during multiple pass sideressing of an octagonal workpiece into a circular cross-sectionedhape. Dyja et al. (2004) used three-dimensional FEM to investigatehe effect of some complex die shapes on the deformation patternsn open die forging. They validated their calculations with labo-atory scale experiments using steel as the workpiece. Choi et al.2006) used three-dimensional FEM to optimize the open die forg-ng process for conversion of a rectangular/square cross-sectioned

orkpiece into one with a circular cross section. They focused oneed rate and rotation angle in the study. It is evident from thesetudies that FEM simulations can be very helpful in understandingnd controlling open die forging processes. Furthermore, the defor-ation behavior has also been analyzed by FEM in conjunction with

onstitutive model. Yoon et al. (2010) predicted plastic flow behav-or by considering an operating deformation mechanism and strainardening model.

One of the main benefits of open die forging is the ability to closenternal voids that come for cast ingots. There have been a numberf previous studies examining how to operate the open die forgingrocess to best close these internal voids. Dudra and Im (1990b)xtended their two-dimensional FEM analysis to study the closuref centerline pores during side pressing of circular shaped billetssing dies with various shapes. From their analysis they indicatedhat effective strain appears to be a better indicated of void closurehan hydrostatic stress. Park and Yang (1996) proposed a bonding

echanism based on hot pressing that could help in studying thelosure of voids during open die forging. Park and Yang (1997a)sed three-dimensional FEM together with a Taguchi set of experi-ents to study void closure during open die forging of large ingots.

t appears that they assumed centerline voids in the analysis. Theyound that the die width ratio and proper die shape are beneficial inlosing voids whereas cooling of the ingot surface does not appearo be helpful for void closure. They also provide some insight onhe bonding efficiency as the void surfaces came together. Park andang (1997b) extended their bonding efficiency study with FEModeling and experiments. They also investigated the bonding asfunction of void position in the ingot. They found that die shape in

onjunction with reduction in height controls the bonding process.

Kim et al. (2002) developed a neural network algorithm for thelosure of voids in open die forging of rectangular cross-sectionedorkpieces. They studied a large number of process parameters

nd used the algorithm to recommend a forging pass schedule

nd internal void of cast ingot.

that would close voids effectively and efficiently. Overstam and Jarl(2004) used three-dimensional FEM to examine the closure of cen-terline voids in rectangular cross-sectioned workpieces. They foundthat the bite ratio was a critical factor in getting the pores to close.Banaszek et al. (2005) and Banaszek and Stefanik (2006) used two-dimensional FEM to study the effect of die shape and other processparameters on void closure in open die forgings. They examinedvoids at various locations in the ingot and provided verificationwith experimental tests using a highly alloyed steel. They foundthat die shape had a major effect on void closure and advocated theuse of shaped dies during the initial stages and flat dies during thefinal forging stages to achieve best results. Chun et al. (2006) exam-ined the closure of centerline voids in rectangular cross-sectionedworkpieces using three-dimensional FEM. They studied the effectof die width ratio, die feed rate, die shape, and number of passeson the closure of voids. Skubisz et al. (2008) studied the closureof centerline voids during open die forging both numerically andexperimentally. They found that a critical amount of effective strainwas needed to close these voids. Lee et al. (2008a,b) used three-dimensional FEM to examine centerline void closure during theaxial compression of cylindrical workpieces. They found that a crit-ical amount of effective strain was needed to close the voids. Zhangand Cui (2009a) developed an analytical model for the closing of aspherical void during axial compression of a cylinder. They verifiedtheir model using two-dimensional FEM. Zhang et al. (2009b) indi-cated that void closure in forgings is a multi-scaled problem andthey developed a mesomechanics approach to the issue. They indi-

Fig. 2. Flow chart to investigate the void closure of cast ingot in open die forging.

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1138 Y.S. Lee et al. / Journal of Materials Processing Technology 211 (2011) 1136–1145

Fig. 3. Microstructure and flow stress of cast ingot and wrought material.

res and dimensions used in model.

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Table 1Volumes and positions of voids.

No. � (mm) Volume of void(mm3)

Volume percentage of void relativeto the total specimen (%)

P1 82 353 0.028P2 102 276 0.022P3 185 256 0.020

Fig. 4. Experimental procedu

ate sensitivity exponent) and four numerical values that wereetermined as a function of the Norton exponent via FEM analysisnd regression. Kakimotoa et al. (2010) used both two-dimensionalnd three-dimensional FEM to study the closure of centerline voidsuring axial compression and side pressing of circular and rect-ngular crossed-sectioned forgings. They calculated a void closingndex, Q-value, which must achieve a value of 0.21 to insure voidlosure. They indicate that the Q-value uses Oyane’s equation andas initially proposed by Ono et al. (1993).

Void closure has also been studied in other large shapes pro-uced by deformation. Hamzah and Ståhlberg (1998) studied pore

losure in manufacturing of heavy rings using two-dimensionalEM. They found that piercing of the initial hole in a closed con-ainer produced a pore free ring whereas open die piercing of theole did could produce a final ring with pores. They attributed theuccessful manufacturing route to the large strains created during

P4 189 268 0.021P5 189 325 0.026P6 189 22,280 1.752

the piercing in a closed die. Hamzah and Ståhlberg (2001) extendedtheir ideas in proposing a new route for producing pore free rings,which primarily depended on high strains during piercing and sub-sequent forming. They also found that the hydrostatic pressure wasa less critical parameter for pore closure.

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Y.S. Lee et al. / Journal of Materials Processing Technology 211 (2011) 1136–1145 1139

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Fig. 5. Scanned internal void

.2. Objective of study

It is evident form these previous investigations that effectivetrain is an important parameter in determining whether or not a

oid will close. Although stating that effective strain is important,any studies do not give the specific amount needed for effective

oid closure. It is also interesting to note that several of the studiesave found that hydrostatic stress is a less important parameter in

Fig. 6. Shape and size of scanned in

3D-modeling for FE analysis.

void closure as compared to effective strain. Although Kakimotoaet al. (2010) have proposed a very specific criterion for void clo-sure during open die forging, their criterion is fairly complex andrequires knowledge not only of the effective strain, but also the

effective stress, the hydrostatic stress as well as some flow prop-erties of the material. Although a good theoretical study, it wouldbe difficult to implement their criterion in a production environ-ment.

ternal voids after first upset.

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1140 Y.S. Lee et al. / Journal of Materials Processing Technology 211 (2011) 1136–1145

f round ingot after first upset.

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Table 2Void deformation patterns after two upsets at right angles to each other.

Case no. First upset Second upset

due to scan limits of ferrous metals. The sample was scanned usingan X-ray scanner (VendoTM H-450CT) to determine if it had internalvoids. When an internal void was found in the sample, the void wasquantitatively characterized for incorporation into the simulationanalysis. Table 1 and Fig. 5 show the size and shapes of the various

Fig. 7. Deformed shape o

The present study is concerned with the elimination of the inter-al voids in large ingots so as to obtain a sound final product. Mostf the previous studies have only investigated voids in the center ofhe workpiece rather than throughout. In the present study voidst various locations in the workpiece are investigated and a specificriterion for the amount of effective strain needed for void closures proposed base on the analysis of the results generated. The crite-ion for eliminating internal voids provides important informationor the design and operation of an open die forging process thatesults in a good quality, sound product.

In this study, hot compression tests were conducted to obtainhe flow strength of cast ingot material at different temperaturesnd strain rates. FEM simulations were performed to investigatehe deformation behavior of cast ingots during the various forg-ng stages. The measured flow strength data as well as appropriatehermal property data were used to simulate the upsetting processf cast ingot. DEFORM-3DTM was used to perform the numericalnalysis of void closure. The calculated results for void deforma-ion behavior are compared to experimentally measured resultsefore and after upsetting of actual ingots/forgings, which wereetermined by X-ray scans. From the comparison of the numericalimulations and experimental results, the criterion for the amountf deformation needed for void closure was developed. Fig. 2 showshe flow chart for this investigation into void closure of cast ingoturing the initial upsetting stages of open die forging.

. Experiments

.1. Flow strength of cast ingot material

The material used in this study was AISI4140 (SCM440). Its initialorm was a cast ingot with the three zones typical of cast struc-ures – columnar, chill, and equiaxed. Cylindrical specimens were

achined from material in the equiaxed zone. These specimensere tested to determine the flow strength of the cast ingot mate-

ial by hot compression testing using a hot deformation simulator,hermecmaster-ZTM. Fig. 3 shows that the measured flow strengthf the cast structure is quite different from that of the wroughtaterial. The flow strength of the wrought material is over 30%

reater than that of the cast material. Flow strengths were mea-ured at three temperatures and three strain rates. These measuredalues were used in the DEFORM-3DTM simulations. Because of theifference in the flow strength values between cast and wroughtaterial, it was important to use the appropriate values in the sim-

Case 1 Void closed Remained as closed voidCase 2 Void closed Opened againCase 3 Void not closed Remained as open void

ulations. The use of the wrought properties for this study could havegenerated significant errors in the results from the FEM analysis.

2.2. Void closure – initial upset

Fig. 4 shows the hexahedral cast-ingot that was used to inves-tigate void closure, by experimental upset deformation and FEManalysis. The ingot was casted intentionally to include many kindsof voids so an investigation on variables, such as size and positioncould be conducted. The round ingot was machined from hexahe-dral cast-ingot into a cylindrical sample with a diameter of 90 mm

Fig. 8. External shape of upset specimen from experimental and analysis results.

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Y.S. Lee et al. / Journal of Materials Processing Technology 211 (2011) 1136–1145 1141

of w

vtopTivss

Fig. 9. Fine mesh system

oids that were found. Six representative void shapes were used inhe three-dimensional FEM simulations. These shapes were of voidsf different shapes and sizes and the voids were located at differentositions in the ingot as well as different positions in the sample.

he cylindrical sample with voids was upset (side pressed) and thent was rescanned to experimentally compare resulting changes inoid geometry with the FEM analysis. Fig. 6 shows the shape andize of the internal voids after this initial upset. Fig. 7 shows thehape of the upset sample both experimentally and predicted by

Fig. 10. Temperature changes of workpiece from heati

orkpiece and FE model.

the simulation. After upsetting the large internal void on the rightside of the sample decreased in width as compared to the void onthe left side. These changes in void geometry were observed in boththe experimental results and the FEM results. This match of results

provided confirmation of the validity of the numerical simulations.Based on the favorable comparison for the laboratory experiments,it appears that an FEM analysis can accurately predict the deforma-tion patterns and the void closure process during the upsetting ofa cast ingot.

ng through transfer to hot forging on first upset.

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1142 Y.S. Lee et al. / Journal of Materials Processing Technology 211 (2011) 1136–1145

ve stra

2

vtflddottdocu

Fig. 11. Applied load and effecti

.3. Deformation behavior of voids – second upset

During open die forging, internal voids generally deform inarious directions due to the multiple blows imparted duringhe upsetting or cogging stage. Each void may have a uniqueow pattern. In this study, the sample with voids that waseformed by the initial simple upset was given additional plasticeformation after rotation of 90◦. Fig. 8 shows how this sec-nd upset deformation was applied to the sample. Table 2 listshree types of void deformation patterns that were observed. In

he first case, a void closed by first upsetting remained closeduring the second step. In the second case, a closed void re-pened during the second step. In the third case, a void notlosed during the first upset was not closed during the secondpset.

Fig. 12. Deformed shapes of intern

in distribution after first upset.

3. FEM analysis

3.1. FE model and material properties

Fig. 5 shows the six voids that were analyzed by finite elementanalysis. The voids were assumed to be holes with vacuum. A veryfine mesh system was used in the simulations in order to avoidremeshing. If the original mesh becomes too distorted and remesh-ing occurs, then the nodes on the deformed voids might be mergedduring the remeshing, causing an inappropriate closure during the

simulation. If such remeshing is the cause of closure, then the criti-cal conditions for void closure cannot be accurately predicted. Fig. 9shows that the number of elements used in the simulations is on theorder of 150,000. Table 3 lists the process conditions and materialproperties used in the simulations.

al voids after second upset.

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Y.S. Lee et al. / Journal of Materials Processing Technology 211 (2011) 1136–1145 1143

Table 3Process conditions and material properties.

Process conditions Material properties

Material AISI-4140 Flow strength Measured valuesBillet temperature 1100 ◦C Elastic

modulus205 GPa

Punch velocity 2 mm/s Coefficient ofthermalexpansion

12.2–14.6 �m/m ◦C

Material model Die: rigid Heat capacity 0.473–0.561 J/g ◦CWorkpiece:

3

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Fig. 13. Deformation behaviors of voids according to forms of internal voids dur-

viscoplasticThermalconductivity

33–42.6 W/m K

.2. Plastic deformation of ingot – initial upset

The temperature of the workpiece decreased during the trans-er from furnace to press. When the workpiece was deformed,he temperature increased because of the thermal energy gener-ted by the deformation process. Fig. 10 shows the temperatureariation where the workpiece first decreased to between 900nd 1000 ◦C and then increased to temperatures up to 1120 ◦C.here was some local surface cooling where the workpiece wasn contact with the die. The effective strain is largest in the inte-ior of the forged billet and much smaller on the surface of theillet. As Fig. 11 shows, the applied load was 270 tons duringhe experimental tests. Whereas, the load predicted by the FEMimulation results was 290 tons. The difference in these loads isikely due to difference in the surface temperature of the billet.n production the surface of a forged billet possesses an oxideayer, which can provide some insulation causing the interior tem-eratures to be a little higher than would be predicted by theimulation where the oxide surface layer is not part of the model.ue to this oxide layer, the higher applied load from the FEMnalysis should be considered consistent with the experimentalesults.

.3. Simulation of void closure – second upset

The largest void among the six that were analyzed by FEM isocated in right side of the sample as show in Fig. 12. The othersve voids are located in different positions. Shear stresses wereresent at these void locations during the initial upset step as wells during the second upset. The largest internal void evolved in aomplex manner. In certain cross-sectional views the internal voidppeared to re-open and in other cross-sectional views it appearedo close. For example the cross-section no. 9 remained closed duringhe second upset, however, cross-section no. 1 was not closed evenfter the second upset.

Some of the small voids were closer during either the first or theecond upset. Others voids were closed during the first upset andhen re-opened during the second. The different closure behaviorsuring the deformation were influenced by the size and location ofhe individual void. Fig. 13 shows the detailed changes to the voidsuring the deformation.

. Discussion

.1. Criterion of void closure during a simple upset

Among voids that were investigated as part of this study, somelosed and others did not close during the upsetting processes.ig. 14 shows that three voids, P1, P2 and P3, were closed. Theydrostatic stress at these locations went from a tensile valuehrough a compression value and then back to tensile. The tran-

ing two upsettings. (a) Case1: closed void → void closed → void remained closed,(b) Case 2: open void → void closed → void opened again, and (c) Case 3: openvoid → void not closed → void remained open.

sition of hydrostatic stress related to void closing is representedin P1, P2 and P3. Fig. 14 shows these hydrostatic stress changes.When the stress state was compressive, the value was near theflow strength of the material. The points near to the closed voidwere initially expanded in the direction of the upset and then theywere compressed after the void closed. Fig. 15 provides a schematic

drawing of this sequence. Based on these results, it can be sug-gested that a compressive stress equal to the flow strength of thematerials should be applied in order to close void. Practical FE sim-ulations of cast-ingot forging are performed in the absence of voidsbecause specifics of the voids are often unknown a priori. Therefore,
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1144 Y.S. Lee et al. / Journal of Materials Processing Technology 211 (2011) 1136–1145

Fig. 14. Hydrostatic stress around void during forging.

atssgo

shows surface voids that could not be closed during the two hotupsets. The applied effective strain was less then the threshold

Fig. 15. Stress change of void at contact point.

criterion based upon strain rather than on stress would be easiero implement in a practical industrial environment. The necessarytress condition for void closure is achieved if the local effective

train is greater than 0.6, as Fig. 16 shows. Therefore, we can sug-est that the criterion of void closure is a local effective strain of 0.6r greater.

Fig. 17. Effective strains and vo

Fig. 16. Effective strain near voids during forging.

4.2. Open voids and closed voids

Various kinds of voids react to the upset differently. Table 1classifies three forms of voids as how they deformed differently.

Closure of the void occurred during plastic deformation whenthe local effective strain applied to the sample was greater than 0.6,as shown in Fig. 13(a). On the other hand, when the local effectivestrain of less than 0.6 was applied, the void did not close duringeither of the two upsets as illustrated in Fig. 13(b). Therefore, thethreshold strain to achieve void closure is 0.6. Although volumesof P2 and P3 are almost same as shown in Table 1, the P3 void didnot closed. Since the P3 void is located nearby the P6 void the accu-mulated effective strain on the P3 void is smaller than the P2 void.The local strain value is about 0.48 which is under the thresholddeformation amount needed for void closure.

If a void is located on a surface, the void may not close. Fig. 13(c)

value needed for closure at both of these surface void sites.The proposed criterion based on an effective strain value was

confirmed again as shown in Fig. 17. Three cases are presented that

id closures for each case.

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tive model considering elongation at yield point. Kor. J. Met. Mater. 48 (7),598–604.

Zhang, X.X., Cui, Z.S., 2009a. Theoretical study of void closure in nonlinear plasticmaterials. Appl. Math. Mech. – Engl. Ed. 30, 631–642.

Y.S. Lee et al. / Journal of Materials Pro

llustrate the importance of straining to a critical value in order tochieve void closure. Void closure is dependent on reaching theritical effective strain whether the void is a surface void or annternal void. A critical value of effective strain for void closures a very efficient and practical parameter to base the criterion on.t is better than other parameters, such as the hydrostatic stress,ince the strain value can be determined from FEM simulations ofpsets even if the voids are not present in the simulation. The actualydrostatic stress state for the material near a void would not beccurate in the FEM simulations if the void were not incorporatednto the model. Parameters related to voids inside a cast ingot can-ot be easily analyzed because it is difficult to know the specific site,hape, and location of the void prior to running the simulation.

. Summary

The results from FEM simulations of void closure behavioruring the forging of cast ingots have been compared with exper-

mentally measured void geometries both before and after upsetorgings. An X-ray scanner can monitor voids experimentally. Fromhe combined experimental and numerical results the amount ofeformation needed to close a void closure was determined and ariterion has been proposed in terms of effective strain. Hydrostatictress affects the void closure and previous studies have shownesults related to the hydrostatic stress value. However, hydro-tatic stress is not as useful for practical process design becausehe numerical analysis used during design may not give the correctydrostatic stress distributions when internal voids in the ingot areot present in the simulations. Hence, effective strain, which is aarameter independent of the presence or the absence of an inter-al void in the simulation, is a more practical variable upon whicho base a criterion for void closure.

In this study, changes of hydrostatic stress and effective strainuring two upset steps were investigated to determine whether theoid closed or not. From these results, we know that the transitionoints of hydrostatic stress related to void closing and that effectivetrain of 0.6 or greater provides an adequate condition for the clo-ure of internal voids during forging. Other conclusions obtainedrom this study are as follows:

1) During the upset the hydrostatic stress around the voids wentfrom a tensile value through a compressive value back to atensile condition. The compressive values were close to flowstrength of the material. The material nearby a closed void ini-tially expanded in the upset-direction and then compressedafter the void closed. It is suggested that a compressive stressshould be applied to close the voids. The criterion of an effec-tive strain of over 0.6 achieves the conditions for void closureduring forging.

2) Various void behaviors can be observed during the upset forg-ings. Three behavior types were found. The type of behaviorexhibited by a single void depended on its size and locationwithin the ingot.

3) From the results, we propose that effective strain be used duringforging process design. This measure allows numerical sim-ulations for determination of void closure conditions to beperformed without requiring the presence of an internal voidwithin the simulation.

cknowledgement

This work was partially supported by grants-in-aid for theational Core Research Center Program from MOST/KOSEF.

g Technology 211 (2011) 1136–1145 1145

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