Hawryluk Marek, Polak Sławomir, Rychlik Marcin, Barełkowski Artur, Jakuć Jakub, Marzec Jan
Department of Metal Forming, Welding and Metrology, Wroclaw University of Science and Technology, Lukasiewicza Street 5, 50-370 Wroclaw, Poland.
Kuźnia Jawor, Kuziennicza 4 Street, 59-400 Jawor, Poland.
Materials (Basel). 2024 Jul 3;17(13):3281. doi: 10.3390/ma17133281.
This article presents research results regarding the development of a new manufacturing technology for an element assigned to belt conveyor flights in the extractive industry through hot die forging (of a forging with a double-sided flange) instead of the currently realized process of producing such an element by welding two flanges onto a sleeve or one flange onto a flange forging. The studies were conducted to design an innovative and low-waste technology, mainly with the use of numerical modelling and simulations, partially based on the current technology of producing a flange forging. Additionally, during the development of the forging process, the aspect of robotization was considered, both in respect of the forging tools and the process of transportation and relocation of forging between the impressions and the forging aggregates. A thermo-mechanical model of the process of producing a belt conveyor flight forging with deformable tools was elaborated by means of the Forge 3NxT program. The results of the conducted numerical modelling made it possible, among other things, to develop models of forging tools ensuring the proper manner of material flow and filling of the impressions, as well as temperature and plastic deformation distributions in the forging and also the detection of possible forging defects. For the technology elaborated this way, the tools were built together with a special instrument for flanging in the metal, and technological tests were performed under industrial conditions. The produced forgings were verified through a measurement of the geometry, by way of 3D scanning, as well as the hardness, which definitively confirmed the properness of the developed technology. The obtained technological test results made it possible to confirm that the elaborated construction, as well as the tool impressions, ensure the possibility of implementing the designed technology with the use of robotization and automatization of the forging process.
本文介绍了一项关于开发一种新制造技术的研究成果，该技术用于采矿业中带式输送机刮板的一个部件，采用热模锻（双面法兰锻件）来制造，而非目前通过将两个法兰焊接到一个套筒上或将一个法兰焊接到法兰锻件上来生产该部件的工艺。开展这些研究是为了设计一种创新且低浪费的技术，主要利用数值建模和模拟，部分基于当前法兰锻件的生产技术。此外，在锻造工艺开发过程中，考虑了机器人化方面，涉及锻造工具以及锻件在模膛和锻造设备之间的运输与重新定位过程。借助Forge 3NxT程序，建立了带有可变形工具的带式输送机刮板锻件生产过程的热-机械模型。所进行的数值建模结果使得能够开发出确保材料正确流动和充满模膛的锻造工具模型，以及锻件中的温度和塑性变形分布模型，还能检测出可能的锻造缺陷。对于这样精心设计的技术，制造了工具以及一种用于金属翻边的特殊仪器，并在工业条件下进行了工艺试验。通过3D扫描测量几何形状以及检测硬度，对生产出的锻件进行了验证，这最终证实了所开发技术的正确性。所获得的工艺试验结果能够确认，精心设计的结构以及工具模膛确保了利用锻造过程的机器人化和自动化来实施所设计技术的可能性。
