Idea Transcript
Viking Forge Corp. If you want to be sure… FORGE IT!!!
Viking Forge An ISO 9001:2000 Company
Offices: 4,000 Square Feet Tool & Die Shop: 12,000 Square Feet Forging Operations: 78,000 Square Feet 20 Acres Of Land For Future Expansion
Tool Making Equipment 1 Daewoo Puma 200 CNC Turning Center 1 Daewoo Puma 400 CNC Turning Center 2 Hermle C800V CNC Vertical Machining Center 1 Hermle C1200U 5 Axis CNC Vertical Machining Center 1 Alpha 1550S Lathe 2 VKM3 Milltronics Partner Mills 1 Fully Automated Die Welding Cell Miscellaneous support equipment
Steel Cutting Equipment 1 1 1 1 2 1
600 Metric Ton Ficep Fully Automated Hydraulic Shear 4” Diameter Amada CM-100 Automated Cold Saw 4” Diameter Nishijimax NHC-100 Automated Cold Saw 6” Diameter Nishijimax NHC-150 Automated Cold Saw 12” X 16” Amada HA400 Automatic Saws 10” X 12” Amada HA250 Automatic Saw
Heating & Forging Equipment 2 3 1 1 1 1 1 1 1
400 kW Inter-Power Induction Heating Billet Furnaces 1250 kW Inter-Power Induction Heating Billet Furnace 2000 kW AEG Elotherm Induction Heating Billet Furnace 1300 Ton National Forging Press 1600 Ton Bliss Forging Press 1600 Ton National Forging Press 2500 Ton National Forging Press 2500 Ton Erie Forging Press 4000 Ton Erie Forging Press
Finishing & Inspection Equipment 2 1 1 1 1 1 1 1 1 1
24 Cubic Foot Goff Tumble Blast Machine 3 Cubic Foot Wheelabrator Tumble Blast Machine 700 Ton Chester Hydraulic Cold Coining Press 110 Ton Waterbury Hydraulic Cold Coining Press New Age 9000 Automatic Brinell Tester New Age ME-2 Automatic Rockwell Tester MagnaFlux Magnetic Particle Inspection Machine Brown & Sharpe Excel 7-10-7 CMM Mitutoyo B715 CMM Mitutoyo PH350 Optical Comparator
Engineering Software • • • • •
SolidWorks 3-D Solid Modeling CAD System SmarTeam Product Data Management System SmartFlow Workflow Management System Q-Form 3-D Finite Element Analysis GibbsCAM CNC Programming System
Quality Assurance Software
• • • • •
PC-DMIS CMM Programming System DataPage CMM Statistical Data Collection System Kurt Check SPC Data Collection System GAGEtrak Calibration Management System Minitab Statistical Analysis System
Forging Defined • Forging is the plastic deformation of metal into desired shapes using custom tooling and specialized equipment. • It can be performed at various temperatures as defined below: - Cold Forging - 0 to 500o Celsius - Warm Forging - 500 to 800o Celsius - Hot Forging - 800 to 1100o Celsius
Basic Impression Die Forging
Hammer or Press
In the most basic example of impression die forging, which accounts for the majority of forging production, two dies are brought together and the workpiece undergoes plastic deformation until its enlarged sides touch the die side walls Then, some material begins to flow outside the die impression, forming flash. The flash cools rapidly and presents increased resistance to deformation, effectively becoming a part of the tool. This builds pressure inside the bulk of the workpiece, aiding material flow into unfilled impressions.
Typical Mechanical Press
Typical Forging Progression
Precision Forging • Forging close to finished size to minimize machining • Tolerances tighter than typical • Refinement and improvement of existing forging practice • Limited to extremely high quality applications due to economics • Complex geometries
Conventional vs. Precision Forging Before
After
Complex Shapes
Flashless Forging • Flashless forging is a type of precision forging • Die cavity is completely closed during forging process • Volume control is critical • Requires stringent process controls • Additional forging costs are offset by reduced machining costs
Forging Video
Forging Tooling Case Studies
Tool Steel Case Study # 1 Turbine Hub LUK / Allison Transmission / GM
Turbine Hub Solid Model
49109201.EPRT
Solid Model of Bottom Finish Die
New Bottom Finish Die
Forge & Trim Die Assembly Solid Models
b1092fa.EASM
Forge
b1092ta.EASM
Trim
Finite Element Analysis/ Material Flow Simulation
Comparative Results: Bottom Finish Die
Material
Failure Mode
Die Life
Standard H-13 Dievar
Wear Wear
17,420 39,626
Overall Improvement: 220% LUK / Allison Transmission / GM
Comparative Results: Trepan Tool
Material
Failure Mode
Die Life
Std./ESR H-13 Dievar
Wear Wear
4,250 7,370
Overall Improvement: 73% LUK / Allison Transmission / GM
Tool Steel Case Study # 2 Drive Flange Magna Steyr / ZF / Mercedes
Drive Flange Solid Model
49116101.EPRT
Solid Model of Bottom Finish Die
New Bottom Finish Die
New Bottom Finish Die Insert With Shrink Ring Assembled
Forge & Trim Die Assembly Solid Models
a1161fa.EASM
a1161ta.EASM
Forge
Trim
Finite Element Analysis/ Material Flow Simulation
Comparative Results: Bottom Finish Die Material Standard H-13 Dievar
Failure Mode
Die Life
Breakage 67% wear 33% breakage
2,650 5,990
Overall Improvement: 126% Magna Steyr / ZF / Mercedes
Comparative Results: Top Finish Die
Material
Failure Mode
Die Life
Std./ESR H-13 Hotvar
Wear Wear
2,146 6,251
Overall Improvement: 191% Magna Steyr / ZF / Mercedes
Tool Steel Case Study # 3 Wheel Hub Tochigi Fugi / GKN / Bombardier
Wheel Hub Solid Model
49117401.EPRT
Solid Model of Bottom Finish Die
New Bottom Finish Die
New Bottom Finish Die
Forge & Trim Die Assembly Solid Models
b1174fa.EASM
Forge
b1174ta.EASM
Trim
Finite Element Analysis/ Material Flow Simulation
Comparative Results: Bottom Finish Die
Material
Failure Mode
Die Life
Standard H-13 Dievar
Wear Wear
2,600 5,360
Overall Improvement: 110% Tochigi Fugi / GKN / Bombardier
Comparative Results: Top Die Posts
Material
Failure Mode
Die Life
Standard H-13 Hotvar
Wear Wear
1,450 3,110
Overall Improvement: 115% Tochigi Fugi / GKN / Bombardier
In Summary…
Design Factors that Affect Tooling Cost • • • • • • •
Thin sections Number of holes and their proximity Radii and fillets Surface finish and cosmetics Special markings/identification Stock allowance Tolerances
Tooling Cost Components Relative Importance Design Tool steel Heat treat Nitride Machining
Percent of Total Cost Machining Design Tool steel Nitride Heat treat
Tool Steel Supplier Evolution • Past Practice – H-13 is H-13 – Many Suppliers – Lowest Price Wins
• Current Practice – – – –
H-13 is not H-13 Match Grade with Application 2 Suppliers Highest Quality at a Competitive Price
Historical Purchases Uddeholm
• • • •
2003 2004 2005 2006
-
$0 $10,000 $470,000 $510,000
Tool Steel Heat Treat & Nitride • Past Practice – – – – –
Heat Treat is Heat Treat, Nitride is Nitride Multiple Heat Treaters and Nitriders Multiple Heat Treat and Nitride Processes Hardness Call-out 48-52 HRc Lowest Price Wins
• Current Practice – – – –
Single Heat Treat and Nitride Source Match Process with Application Hardness Based on Die Size and Configuration Must be Competitive with Like Processes
Future Expectations for Tool Steel • Greater Strength • Better Wear Resistance • Not Necessarily Lower Cost
Questions and Answers
THANK YOU UDDEHOLM TOOLING THINK FORGING!!!