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ORGANIZER;CN=ESTAD 2023:mailto:info@metec-estad.com
LOCATION:Room 28
SUMMARY:Best practice analysis of an industrial cogging process for a tool steel ingot
DESCRIPTION:Cogging is an incremental forming, open-die forging process that is used to produce rectangular, round or hexagonal semi-finished products with high demands in terms of mechanical properties and microstructure and is applied in many industrial fields, e.g. the tool manufacturing and automotive industries. An industrial cogging process for a 3.3-ton X38CrMoV5.1 tool steel ingot and the material properties of the ingot are comprehensively analyzed as part of the process validation, with an emphasis on studying the core deformation and gaining greater process knowledge.
Material properties are obtained from a 2-ton X38CrMoV5.1 ingot. Cross-sectional boards at the foot (F), half-length (M), and head (H) plus one longitudinal board are sawn out of the ingot.
Hot-working yield curves are determined at three different radial positions in the cross-sectional boards (F, H, M). The yield curves obtained for the core, filet, and edge at all length positions show negligible differences. Furthermore, the yield stress in the foot and head differs less than 6% from that at half-length. The hot-working yield strength is quite homogeneous throughout the ingot and does not significantly differ from the yield strength of the forged material.
A metallographic analysis is conducted with the aid of the “HD scan” ultrasonic inspection system. The sawn boards are scanned and analyzed. A typical cast structure, free of shrink holes but with imperfections in the core, is observed. Traditional metallography provides a reference for the microstructure.
In-depth process data are obtained from thermographic measurements and data logging during the cogging process on a 10-MN hydraulic open-die forging press.
The FE-simulation of the 12-pass cogging process corresponds closely with the real process sequence. The calculated force shows only slight variations, and the final temperatures agree closely with the measurements. The quite homogeneous equivalent plastic strain in the core along the length of the block exceeds 1.5 throughout and 
CLASS:PUBLIC
DTSTART:20230615T115000
DTEND:20230615T121000
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