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Oleśnica, Poland

Gronostajski Z.,Wroclaw University of Technology | Kaszuba M.,Wroclaw University of Technology | Paschke H.,Fraunhofer Institute for Surface Engineering and Thin Films | Zakrzewski T.,GKN Driveline Olesnica | Rogalinski G.,GKN Driveline Olesnica
Archives of Metallurgy and Materials

In the process of die hot forging the tools are subjected to three main factors leading to their destruction: the intensive thermal shocks, cyclically variable mechanical loads and intensive friction. The above mentioned factors causing destruction in the process of hot forging and warm forging concern mainly the surface of tools. Hybrid technique nitrided/PECVD belong to the latest methods of modifying the properties of the surface layer. In the paper the application of this technique for forging tools of constant velocity joint body is presented. The durability of the new tools is much better than the tools applied so far. Source

Gronostajski Z.,Wroclaw University of Technology | Hawryluk M.,Wroclaw University of Technology | Kaszuba M.,Wroclaw University of Technology | Sadowski P.,Wroclaw University of Technology | And 2 more authors.
Eksploatacja i Niezawodnosc

The paper presents portable measuring & control systems, designed and built by the authors, and their application to the analysis of two industrial processes: the precision hot forging of CV universal joint casings in closed dies in the crank press (GKN Driveline Oleśnica) and the forging of concrete slab carrying handles in a TR device in the eccentric press (INOP Poznań). The systems enable the measurement, archiving and analysis of forging force-time/displacement traces correlated with tool temperature, as well as the measurement of production speed and the quantity of produced forgings. Recently an acoustic emission (AE) signal registration capacity has been incorporated into the system to investigate the changes occurring during the forging process, especially progressive tool wear. The information obtained in this way is to be used to improve the operating conditions of the forging presses and to optimize the whole forging process by means of CAD/CAM/CAE software based on FEM. The measuring & control systems consist of an industrial computer (comprising a real-time controller, a multi-speed measurement card, RAM memory, large capacity hard disks and a set of amplifiers and transducers) and sensors (force, displacement, pyrometers, thermocouples, linear and angular encoders, accelerometers and AE). Two applications (based on LabView) have been developed for each of the systems. One of the applications is installed on the industrial computer and is used to control the system as well as to record and process the voltage signals received from the individual sensors. The other application enables the analysis of the processed signals. Source

Gronostajski Z.,Wroclaw University of Technology | Hawryluk M.,Wroclaw University of Technology | Kaszuba M.,Wroclaw University of Technology | Niechajowicz A.,Wroclaw University of Technology | And 3 more authors.
Archives of Metallurgy and Materials

This paper presents the results of a search for an optimal shape of the die for forging CVJ (constant velocity joint) casings. The aim of the optimization was to increase tool life by reducing the pressures acting on the die. Therefore the minimization of the forging force was adopted as the optimization criterion. In order to verify the optimization results, the graphs of the calculated forging forces were compared with the real forging force registered by a dedicated measuring & archiving system. Then new dies with the optimal shape obtained from the numerical modelling were made and used in the industrial forging process. It was found that the maximum forging force values for the optimized dies were by about 10-15% lower than the ones for the dies with the original shape, which indicates an increase in die durability. Source

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