Automated Roll Pass Design by HC121001115947

VIEWS: 4 PAGES: 20

									                   Center for Excellence in Forging Technology




   CEFT – Capabilities (incomplete)


            Long term and short term




Department of Industrial, Welding and Systems Engineering
                        Center for Excellence in Forging Technology


   OSU Facilities and Resources

• Forging Equipment
• Heating Equipment
• Spray Equipment
• In-process Inspection and monitoring
• Tools for off-line characterizing




     Department of Industrial, Welding and Systems Engineering
                             Center for Excellence in Forging Technology

      Mechanical Press Details

Type: Ajax Pitman, Year 1950, Rebuilt in 2000
With new electricals and controls,
New Crank, New Bushings Brass,
New 3 pass fixture,
Condition: Was in operation in 2001

Tonnage: 1300 tons
Weight: 165,000 lbs
Motor: > 5 HP, 1200 rpm, 93 amps
Cycle: 70 strokes per minute

Die Space: 44” x 33”, Floor Space: 11’ X 9’ 4”
Height: 16’3” (16’ above ground)
Shut height: 21.75”, Stroke: 10”
Wedge: 1.625”, Hydraulic Kick
Expected to be Operational by June 2003
          Department of Industrial, Welding and Systems Engineering
                           Center for Excellence in Forging Technology




• Being refurbished by
  Erie Press Systems
• Fitted with
   – New MCU
   – New Operatror
     Panel
   – New Pneumatic and
     Lube System
   – New controls, DAQ
   – Angstrom Tonnage
     monitors
• Inkind donation from
  Erie ~ $95,000

        Department of Industrial, Welding and Systems Engineering
                           Center for Excellence in Forging Technology

     Induction Heater for 1300 Ton Press


• 250 KW heater power, 356 KVA, 250 KW
• Purchased and donated in part by Inter-power Inc.,
  Michigan (in kind assistance ~ $64,000)
• Can heat upto 2” X 6” billet
• Through put 4 lb/min




        Department of Industrial, Welding and Systems Engineering
                            Center for Excellence in Forging Technology

       Lubrication System


•   Donated by CMT (~ $90,000)
•   Airless and Air Assisted Systems
•   Electrically operated Positive Displacement pump
•   Totally adjustable flow rates with +/- 1% flow accuracy
•   Viscosities up to 200,000 cps
•   Pressures up to 3000 psi
•   PC control with data logging
•   Intergraded to operate with mix/dilution station and nozzle
    movers



         Department of Industrial, Welding and Systems Engineering
                     Center for Excellence in Forging Technology




   Mixer / Diluter                        Pump




Department of Industrial, Welding and Systems Engineering
                              Center for Excellence in Forging Technology

        Gleeble 3800
• 20 tons of static force in compression or 10 tons in tension
• Displacement rates as fast as 2000mm/second
• LVDT transducers, load cells, or non-contact laser
  extensometry provide feedback for motion and load
  control
• Fully integrated with LabView
• Expected Fall 2003




           Department of Industrial, Welding and Systems Engineering
                                 Center for Excellence in Forging Technology

          Hydraulic Press


•Used for small scale
testing
Type: Interlakan

Tonnage: 100 tons / 150
ton blank holder
Max speed: .75” / sec
Program Controlled ram
motion




              Department of Industrial, Welding and Systems Engineering
                           Center for Excellence in Forging Technology

     Induction heater for Hydraulic Press

• Induction heater from
  Interpower
• 25 KW power supply
• Maximum billet size
  1” diameter
• Heater equipped with
  a loading magazine
  and a pushrod
• Donated / loaned by
  Interpower



        Department of Industrial, Welding and Systems Engineering
                                        Center for Excellence in Forging Technology




                                                                Hydraulic Press
                 Induction Heater          Temperature
                                           Measurement
Initial Billet




                                                                              Placement of
                                                                                Hot Billet
                                                                                 on Dies




                 Forging of Hot Billet at Room Temperature
                                                             Hot Billet on Dies
                  Department of Industrial, Welding and Systems Engineering
                            Center for Excellence in Forging Technology

       Other Facilities @ CEFT

Wear Characterization:
    – TEM: Philips CM200, Philips CM300 Ultra-Twin FEG,
      Philips EM400T, Philips Tecnai TF20, FEI Dual Beam 235
      FIB
    – SEM: FEI Sirion
    – X-ray diffractometer: Philips XRG3000, Scintag XDS2000,
      Philips XRG3000
Die Thermal Mapping: Thermal Cam (FLIR)
Part Surface Characterization: Hoteye (loaned by OGT
   Technology)
Die Surface Characterization: Mitusubishi Laser CMM (CIS)


         Department of Industrial, Welding and Systems Engineering
                     Center for Excellence in Forging Technology


Laser Measurements – 3D Scanner




                        Comparison shows point information with
                        (i.e.) averages, range, min., max.
 Department of Industrial, Welding and Systems Engineering
                   Center for Excellence in Forging Technology




Details of Press, Fixturing and
Dies for Hydraulic Press




Department of Industrial, Welding and Systems Engineering
                     Center for Excellence in Forging Technology

Hydraulic Press Layout




  Department of Industrial, Welding and Systems Engineering
                     Center for Excellence in Forging Technology

Some dies being tested




  Department of Industrial, Welding and Systems Engineering
                     Center for Excellence in Forging Technology

Instrumented Dies




  Department of Industrial, Welding and Systems Engineering
                           Center for Excellence in Forging Technology

     Die Geometry and Associated Equipment


• 100 mm (4 inches) in diameter / 50 mm (2 inches) in height
• Various heat treat grades of H-13 tested todate
• The dies were heated by 500 Watts electric Band heaters
  manufactured by Chromalox Inc., Pittsburgh, PA.
• Die temperatures were 175°C (350 F) - Temperature was
  checked by an OMEGA touch probe temperature sensor
  (K type).
• The dies were placed on fixtures consisting of two oil-
  hardened steel plates separated by steel blocks to ensure
  a passage for thermocouple wires.



        Department of Industrial, Welding and Systems Engineering
                                      Center for Excellence in Forging Technology


              Other Tests: Multi-scale Tests




                                                                          Spike Test for Closed Die
Ring Test for                                                             Lubrication
Lubrication Evaluation




                                    Product Specific Tests (on 1300 ton
                                    press)


                  Department of Industrial, Welding and Systems Engineering
                            Center for Excellence in Forging Technology

      Research needs – In-kind contribution needs


•   Die material suppliers
•   Machining and heat treat suppliers
•   Coating and surface modification vendors
•   Forging consumable suppliers
•   Forgers
•   Post forging analysis




         Department of Industrial, Welding and Systems Engineering

								
To top