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    Forging Quality in Steel Ingot Manufacturing & Conversion

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    Noel Francis
    TimkenSteel uses advanced modeling tools to optimize steel ingot manufacturing and conversion processes for producing large diameter bars. Through virtual process simulations of casting, forging, and rolling, they can assess center soundness and reduce porosity. A case study showed validation of the simulated results, allowing production of sound bars at lower geometric reduction ratios through an optimized forged-rolled process path compared to rolled-only production. This approach helps TimkenSteel meet customer specifications for soundness in large bars.

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    Forging Quality in Steel Ingot Manufacturing & Conversion

    Uploaded by

    Noel Francis
    97 views20 pages
    TimkenSteel uses advanced modeling tools to optimize steel ingot manufacturing and conversion processes for producing large diameter bars. Through virtual process simulations of casting, forging, and rolling, they can assess center soundness and reduce porosity. A case study showed validation of the simulated results, allowing production of sound bars at lower geometric reduction ratios through an optimized forged-rolled process path compared to rolled-only production. This approach helps TimkenSteel meet customer specifications for soundness in large bars.

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    Forging Quality

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    Forging Quality

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    TimkenSteel uses advanced modeling tools to optimize steel ingot manufacturing and conversion processes for producing large diameter bars. Through virtual process simulations of casting, forging, and rolling, they can assess center soundness and reduce porosity. A case study showed validation of the simulated results, allowing production of sound bars at lower geometric reduction ratios through an optimized forged-rolled process path compared to rolled-only production. This approach helps TimkenSteel meet customer specifications for soundness in large bars.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    97 views20 pages

    Forging Quality in Steel Ingot Manufacturing & Conversion

    Uploaded by

    Noel Francis
    TimkenSteel uses advanced modeling tools to optimize steel ingot manufacturing and conversion processes for producing large diameter bars. Through virtual process simulations of casting, forging, and rolling, they can assess center soundness and reduce porosity. A case study showed validation of the simulated results, allowing production of sound bars at lower geometric reduction ratios through an optimized forged-rolled process path compared to rolled-only production. This approach helps TimkenSteel meet customer specifications for soundness in large bars.

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    Forging Quality in Steel

    Ingot Manufacturing &


    Conversion

    Patrick Anderson
    Manager – Advanced Modeling
    Presentation at Forge Fair 2015 – 4/15/2015
    Overview
    TimkenSteel

    Design for Center Soundness

    Virtual Process Path

    Large Bar Capability

    Conclusions
    TimkenSteel Corporation

    We help customers push the bounds of what’s possible by creating


    steel products and services to overcome their toughest challenges

    Innovative team of experts driving custom and tailored solutions


    • Institutional expertise developed over 100 years
    • Deep technical knowledge of processes and applications
    • ~30% of our product offerings are less than 5 years old

    A 100-year old start-up


    A market leader in
    a broad range of products and services
    Advanced Steel Technology

    Applications Metallurgical Laboratory


    Microscopy
    Advanced Modeling
    Advanced Product & Process Engineering
    Development Labs

    UT

    Corrosion
    ASPEX

    Modeling Software Gleeble


    Dual Beam SEM/FIB
    Design for Center Soundness

    Paradigm shift from reduction ratio to measured soundness


    • Why? – Because TimkenSteel has the knowledge & tools to implement
    • Reduction ratio accounts for geometric shape change only
     How does that tell me what is going on at the center?

    Rolling
    Mill
    AI AF

    Forge
    Press
       ூ
    ி

    • Use virtual process path to assess and predict center soundness


    Steel Ingot Manufacturing & Conversion

    Development Lab
    [Destructive Evaluation]

    Ingot Solidification
    UT Measurement
    [MAGMASOFT]
    [NDE, Validation]

    Rolling Mill Soaking Pits


    [DEFORM, SIMUFACT] [DEFORM, Fluent]

    In-Line Forge Press


    [DEFORM]
    Characteristic of Interest: Soundness
    Goal: Produce large bar (> 9”) sound center product that meets
    customer specifications

    Soundness ≈ Microporosity
    • Cause  volume shrinkage during solidification
    • Mitigate via
     Casting process parameters
     Hot work while converting to bar
    • Important to know where microporosity forms
    Virtual Process Path: Casting

    Niyama criterion value accounts for


    temperature gradient & cooling rate
    during solidification

    Indicates a risk that porosity or


    shrinkage may occur Cross-Section of Ingot in Mold
    Virtual Process Path: Hot Work
    “Hot work eliminates porosity, but the amount
    required to produce full density in bars is a function
    of the method by which the hot work is applied.”
    –ASPPRC Publication1
    Two process paths: Rolled & Forged-Rolled

    With respect to center soundness:

    Forging Reduction ≠ Rolling Reduction

    Overall Deformation = Forging Deformation + Rolling Deformation

    Hot work has to be simulated, evaluated and combined

    1C.V.
    White, G. Krauss, D.K. Matlock, “Solidification Structure and the Effects of Hot Reduction in
    Continuously Cast Steels for Bars and Forgings,” I&SM, Vol. 25, No. 9, 1998, pp. 73-79.
    Virtual Process Path: Open-Die Forging

    Forging Simulation Includes:


    • Incoming Workpiece & Die Geometry
    • Process Parameters

    Tracks key process results that indicate


    evolution of center soundness
    Virtual Process Path: Rolling
    Rolling Simulation Includes:
    • 46” Blooming Mill & 36” Billet Mill
    • Multiple passes through each mill
    Results used to assess soundness
    and final shape
    Virtual Process Path: Validation
    The TimkenSteel Large Bar UT is a
    mechanical inspection machine
    Utilizes reflection transducers and multi-
    element phased array probes
    Inspects for both internal and surface
    indications

    Bar Mid-Radius

    Bar Center

    Bar Mid-Radius
    Example Forged-Rolled
    Bar Center
    large bar inspection scan

    Bar Near Surface


    Virtual Process Path: Results
    “Hot work eliminates porosity, but the amount
    required to produce full density in bars is a function
    of the method by which the hot work is applied.”
    – ASPPRC Publication1
    • Now, with respect to deformation:

    Overall
    + = Deformation
    Distribution

    1C.V.White, G. Krauss, D.K. Matlock, “Solidification Structure and the Effects of Hot Reduction in Continuously Cast Steels for Bars
    and Forgings,” I&SM, Vol. 25, No. 9, 1998, pp. 73-79.
    Case Study: Results Validation
    Physical Process Path: Trial

    Trial Details:
    • Work Piece: Cast blooms
    • Process: Forged-Rolled
    • Sequence: Non-optimized & Optimized
    • Material, initial size and final size all held constant

    Simulations run and post-processed for parameter which


    tracks center soundness

    Simulated tracking results compared directly to measured UT


    indications
    Physical Process Path: Trial Results

    Non-Optimized Process UT Scan [Indications in Red]:

    Optimized Process UT Scan [No Indications]:


    Further Optimization
    Ultrasonic Soundness Specification A

    Com

    Rolled
    Forged-Rolled

    Minimum Reduction Ratio Required


    Conclusions
    Large Bar (> 9”) Quality Map
    Roundness
    Using advanced modeling tools,
    TimkenSteel can bypass the use of
    reduction ratio and focus on Rolled-Only
    optimizing center soundness Product Forged-Rolled

    Soundness
    The Forged-Rolled process path
    Forged-Only
    contains the best of both worlds – Product
    center consolidation of forging
    plus the size control of rolling

    The Forged-Rolled process allows TimkenSteel to produce


    sound, large bar product at geometric reduction ratios
    lower than historically possible in rolled-only product
    We help customers push the
    bounds of what’s possible by
    creating steel products and
    services to overcome their
    toughest challenges
    For more information, visit
    www.timkensteel.com or call us at
    866.284.6536 (USA),
    +44 1455 826320 (Europe),
    +52 (55) 5876 9888 (Latin America),
    +52 (81) 8123-6147 (Mexico) and
    +86 (21) 60231080 (China).
    [email protected]

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