MARTIN AUER GFM Steyr, Austria

Transcription

1 MARTIN AUER GFM Steyr, Austria Precision Bar and Tube Radial Forging of Special Steel GFM GmbH, Austria - V1.2 GFM GmbH all rights reserved

2 BASIC COMPANY DATA (fiscal year 2013) ESTABLISHED: HEADQUARTER: 1945 GFM, Steyr Austria (private) SISTER COMPANY: AMERICAN GFM Corp. Chesapeake Va, USA GFM (UK) Ltd. Wellingborough, England GFM Perm, Russia EMPLOYEES: approx. 400 (combined) 2

3 MILLING HOT FORGING COLD FORGING US CUTTING ROUTING Plant CHESAPEAKE VA. AUSTRIA Plant Steyr 3

4 - PRINCIPLE Incremental forming of rotation symmetrical work pieces 2, 3, 4 (typ.), 6 or. 8 symmetrically arranged tools characterized by sinusoidal movement 4

5 - PRINCIPLE 5

6 TYP. HOT APPLICATIONS 6

7 Applications for Radial forging small Products 7

8 FORGING OF LONG BARS AS CAST Main targets: improve grain structure close porosities FORGED 8

9 INLINE HEATING allows forging of long bars with small diameter allows forging special alloys no interruption of forging process 9

10 FORGING OF REFRACTORY ALLOYS integrated reheating allows a total elongation up to 8:1 even for small diameters refractory alloys are characterized by extremely high melting points used where high temperature strength an corrosion resistance is needed main forged materials are tungsten, molybdenum, tantalum and their alloys forging at temperatures up to 1650 C 10

11 FORGING OF TITANIUM AN ZIRKONIUM ALLOYS Long Bars 11

12 FORGING OF NON MAGNET DRILL RODS AUSTENITIC Cr-Mn STEEL + N THERMO MECHANICAL PROCESS 1. forging of bar in hot condition 2. cool down to defined temperature 3. semi-hot forging below recrystallization temperature 4. strain increased 2 to 3 times 12

13 HOT FORGING OF SEAMLESS TUBES DIE MANDREL ADVANTAGES: high flexibility continious range of diameter excellent quality of pipe inside surface development of new tailormade product produce all kind of formable metals FORGED TUBE JAWS 13

14 Hot forging Forging of Preforms preforms for: turbine blades connecting rods hip joints structural parts typ. materials: stainless titanium cobalt 14 minimal material input minimum flash => less die wear (closed die forging) high flexibility => many different shapes with one set of tool reproducible process => CNC controlled less rejects after closed die forging No grinding after preforming uniform microstructure

15 TURBINE BLADE PREFORMS Billet or upset preform GFM FORGING ROUND ROUND & FLAT - SPIRAL FLAT -SPIRAL MATERIALS: CLOSED DIE FORGING HEAT TREATMENT PRE /FINAL MACHINING no forging stainless steel titanium HEAT TREATMENT PRE /FINAL MACHINING aluminium carbon fibre 15

16 FORGING OF STRUCTUAL RODS structural rods and struts interior Aircraft rods linear rods for flight Control door Lock Rod landing Gear Doors Rods flap & Slat Control rods MATERIALS: stainless steel titanium aluminium carbon fibre 16

17 FORGING OF STRUCTURAL RODS PROCESSING SEQUENCE Titanium 6Al-4V STRAIGHT TUBE MACHINED TUBE (MIDDLE PART) FORGED TUBE ENDS by PROFILED TUBE ENDS by MACHINED END 17

18 BARFORGE WITH FEM ADD IN INPUT DATAS PASS SEQUENCE FORGING PROGRAM 18

19 FEM FORGE FEATURES Total accumulated plastic strain [] Fast 3D simulations due to innovative concept of periodicity Simple automatic setup of simulation from process software (BarForge) Realistic modelling of process kinematics Import of complex hammer geometry Accurate time dependent elastoplastic material model with thermo-mechanical coupling Evaluation of damage and porosity parameters Automatic generation of simulation reports 4 Pass #1 Pass #2 Pass #3 Pass #4 Pass # d [mm] at 0 19

20 Thank you for your attention! 20