City Research Online

Abstract

This thesis describes research into the manufacturing process known as rotary forging. The scope of the work is concerned with the design and construction of a machine to be used for conducting experiments which relate directly to industrial applications of the rotary forging process. The experimental work which includes the forming of wrought materials and the compaction of powder metal, together with the subsequent plastic deformation of sintered powder metal preforms, was conducted primarily to assess performance of the machine. The thesis is presented in two parts. Part 1 relates to design and construction of the machine and Part 2 to experimental rotary forging.

Following a design synthesis formulation of the design requirements for the machine is discussed and the specification derived is stated. Design problems are analysed from fundamental considerations of the kinematics of the rotary forging process. Alternative solutions are discussed and the reasoning which leads to selection of the particular design is given.

The machine configuration selected is an inversion of the kinematic arrangement used by recent workers for research purposes. Features are incorporated in the design which form the subject of applications for patents to be applicable in the United Kingdom and certain foreign countries.

Provision is made in the design for the incorporation of instrumentation appropriate to the range of forging parameters. Description of tooling, ancillary equipment and installation are included.

Experiments to establish the performance of the machine as constructed and to form an initial assessment of the suitability for further development are described.

The objectives, procedures, results, discussion and conclusions are presented for the experiments listed as follows:

1. investigation into the upsetting of cylindrical workpieces,

2. initial investigation into upsetting cylindrical workpieces of low height/diameter ratio using dual conical dies,

3. evaluation of the machine when using contoured upper and lower dies to form a given axisymmetric component from a cylindrical billet,

4. the compaction and post sintered densification of cylindrical powder metal preforms, including development of a method devised to compact hollow cylinders.

It is concluded that the design concept forms a satisfactory basis for a cost effective range of machines applicable to manufacturing industry. Information is made available to aid the design and manufacture of machines, based upon a similar concept.

Modifications to the design are proposed following experience gained whilst conducting experiments. These are included in the suggestions for further work which also contains matters arising from the experimental work. A tentative method of predicting the torque required for platen rotation is presented in an appendix.

Publication Type:	Thesis (Doctoral)
Subjects:	T Technology > T Technology (General) T Technology > TA Engineering (General). Civil engineering (General)
Departments:	School of Science & Technology > Department of Engineering School of Science & Technology > School of Science & Technology Doctoral Theses Doctoral Theses

Export

Downloads