Finite element simulation of ausforming of austempered ductile iron components

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Abstract

The mechanical properties of ductile iron can be improved by ausforming, that is, applying work during austempering. The resulting yield strength and ductility are comparable to those of SAE 4140 steel, while the density is approximately 10 percent less. The viability of manufacturing components by casting a preform, austenitizing it, quenching it to the austempering temperature, forging it, austempering it, and finally, quenching it to the net shape is investigated by simulating the forging operation with finite element analysis. The preform geometry and die set geometry are determined such that the forging operation imparts a reasonably uniform equivalent plastic strain of 20 percent to the workpiece and the prescribed final component geometry is obtained. Forging of two components of varying geometric complexity is simulated using a commercial software package. The results indicate that the geometry of the final part is reasonably close to the goal and that the equivalent plastic strain distribution is reasonably uniform-over 80 percent of the material was plastically deformed 15-25 percent. The design of the preform and die sets appears to be an excellent application for an optimization algorithm.

Original languageEnglish (US)
Pages (from-to)420-425
Number of pages6
JournalJournal of Manufacturing Science and Engineering, Transactions of the ASME
Volume123
Issue number3
DOIs
StatePublished - Jan 1 2001

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Nodular iron
Forging
Geometry
Quenching
Plastic deformation
Software packages
Yield stress
Ductility
Casting
Finite element method
Mechanical properties
Steel
Temperature

All Science Journal Classification (ASJC) codes

  • Control and Systems Engineering
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

Cite this

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title = "Finite element simulation of ausforming of austempered ductile iron components",
abstract = "The mechanical properties of ductile iron can be improved by ausforming, that is, applying work during austempering. The resulting yield strength and ductility are comparable to those of SAE 4140 steel, while the density is approximately 10 percent less. The viability of manufacturing components by casting a preform, austenitizing it, quenching it to the austempering temperature, forging it, austempering it, and finally, quenching it to the net shape is investigated by simulating the forging operation with finite element analysis. The preform geometry and die set geometry are determined such that the forging operation imparts a reasonably uniform equivalent plastic strain of 20 percent to the workpiece and the prescribed final component geometry is obtained. Forging of two components of varying geometric complexity is simulated using a commercial software package. The results indicate that the geometry of the final part is reasonably close to the goal and that the equivalent plastic strain distribution is reasonably uniform-over 80 percent of the material was plastically deformed 15-25 percent. The design of the preform and die sets appears to be an excellent application for an optimization algorithm.",
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year = "2001",
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N2 - The mechanical properties of ductile iron can be improved by ausforming, that is, applying work during austempering. The resulting yield strength and ductility are comparable to those of SAE 4140 steel, while the density is approximately 10 percent less. The viability of manufacturing components by casting a preform, austenitizing it, quenching it to the austempering temperature, forging it, austempering it, and finally, quenching it to the net shape is investigated by simulating the forging operation with finite element analysis. The preform geometry and die set geometry are determined such that the forging operation imparts a reasonably uniform equivalent plastic strain of 20 percent to the workpiece and the prescribed final component geometry is obtained. Forging of two components of varying geometric complexity is simulated using a commercial software package. The results indicate that the geometry of the final part is reasonably close to the goal and that the equivalent plastic strain distribution is reasonably uniform-over 80 percent of the material was plastically deformed 15-25 percent. The design of the preform and die sets appears to be an excellent application for an optimization algorithm.

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