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  • Author: A. Świątoniowski x
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A. Światoniowski and O. Bar

Abstract

The study explores the model of high-frequency vibrations during the continuous rolling processes, the underlying assumption being that vibrations are self-excited. The effects of rolling stand and rolling process parameters on the nature and intensity of vibrations are investigated. The appearance of darkened streaks occurring on the metal sheet is explained. The results are compared with the data quoted in literature on the subject.

Open access

P. Bałon and A. Świątoniowski

Process of metal forming in automotive parts construction becomes more and more demanding due to tightened up tolerance and trials to realize very complex and in many cases unworkable design in mass production. Moreover it is required to cut and limit costs of die production and simultaneously keep high quality. Furthermore, construction elements are more often produced from materials which belong to High Strength Steel or Ultra High Strength Steel. Application of this kind of materials considerably reduces construction mass due to high durability. Nevertheless, it results in appearance of springback effect. Springback value depends mainly on used material as well as part geometry and in extreme cases deviation value from target part might reach in some areas high level. Reduction of implementation time, development of metal components and greater restrictions about designing and producing stamping tools generate extra costs. Designing of dies requires using of appropriate Finite Element Method software to make them more economic and less time-consuming. Therefore analysis of forming process alone is not enough to be taken into account. During the design process it is needed to include the die compensation to reach optimized blank sheet. Prediction of springback effect by tryout method and then correction of deviation is difficult arduous and painstaking. Virtual compensation methods make it possible to receive precise result in a short time. This way gives a huge economic advantage eliminating useless milling and allows to produce of die just in time. Optimization process can relate to individual operation as well as take into consideration intermediate stages in the final result, at the same time increasing the accuracy. Die compensation with software application was experimentally verified by prototype die. Quality requirements regarding products of sheet stamping process are very high due to the technologies of automatic assembly of formed components. Springback, as the main source of drawpieces inaccuracy, is the function of material data, shape of tools and process parameters. Therefore, springback deformation becomes critical problem especially for AHSS steel when the geometry is complex. Hence, it is necessary not only to find springback effect value but also include it during early stage of designing by tooling designers.

Open access

A. Swiatoniowski, J. Sinczak, A. Łukaszek-Sołek and J. Schmidt

Superalloys containing nickel and chromium display high deformation resistance and low plasticity during high-rate plastic forming processes, thus limiting the potentials to improve their mechanical parameters. At the aim to overcome this problem an NiCrN superalloy has been found. In this paper the analysis of forging of this NiCrN superalloy has been presented. Mathematical FEM model of the process are verified by experimental tests run on a double-acting power hammer. Tests reveal, that plastic working of the NiCrN alloy combined with thermal treatment improves its strength by nearly 25%, at the same time its plastic deformability remains the same. Research work has revealed very high resistance to corrosion of the alloy when subjected to stress and marine environment.

Open access

A. Świątoniowski, D. Woźniak and J. Szostak

Abstract

The essential aspect of the MEFASS rolling process is introducing the cyclic axial counter movement of the rolls transverse to the direction of rolling in the course of a band pass through a rolling gap. The effect of a change in the way of deformation obtained in this manner makes it possible to set in one roll pass a deformation several times larger than it is possible in a conventional process. In this paper, upon the basis of the computer model of the MES process, supported by experimental research, the analysis of the influence exerted by the shape of the surface of roll barrels upon the distribution of the intensity of stresses σi and deformations εi in the section of the band being rolled, and also upon the kinematic and force parameters of the process.

Open access

A. Łukaszek-Sołek, A. Świątoniowski, K. Celadyn and J. Sińczak

Abstract

In this paper, the results of investigations into, and of the analyses of, the hot deformation behaviour of the Ni50Cr45N0.6 alloy were presented. Compression tests were conducted on a Gleeble 3800 thermo-mechanical simulator within the following temperatures range 850-1200°C and within that of the strain rate 1-40 s-1 to the constant true strain of 0.9, for the purpose of fulfilling the objective of obtaining experimental stress date. Those data were taken advantage of for the purpose of calculating the workability parameters, and that means the efficiency of power dissipation η, the flow instability ξ and the strain rate sensitivity m. The processing maps based upon Murty’s criterion were drawn up for the following true strain range: 0.2-0.9, and, subsequently, both processing windows and the flow instability areas were determined. For the alloy being analysed, the most advantageous conditions of metal forming were ascertained within the following range of temperatures: 950-1000°C, and for that of the strain rate amounting to 10-40 s-1, and that because of (occurring at the temperature of 950°C) the peak of the efficiency of power dissipation parameter η, amounting to 22% (in accordance with Murty’s criterion). The flow instability areas identified on the processing maps ought to be avoided in metal forming processes. Experimental rolling tests were also conducted.