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Development and Implementation of Die Forging Technology Eliminating Flange Welding Operations in Conveyor Driver
Marek Hawryluk1, Sławomir Polak1, Marcin Rychlik1,2
1Department of Metal Forming, Welding and Metrology, Wroclaw University of Science and Technology, Lukasiewicza Street 5, 50-370 Wroclaw, Poland.
Materials (Basel, Switzerland)
|July 13, 2024
Summary
A new hot die forging technology for belt conveyor flights reduces waste and improves efficiency in the extractive industry. This innovative process integrates robotization for automated manufacturing, enhancing production capabilities.
Area of Science:
- Manufacturing Engineering
- Materials Science
- Extractive Industry Technology
Background:
- Current manufacturing of belt conveyor flights involves welding, which is labor-intensive and prone to defects.
- Existing methods for producing flange forgings lack efficiency and generate significant waste.
Purpose of the Study:
- To develop an innovative, low-waste hot die forging technology for belt conveyor flights.
- To integrate robotization and automation into the manufacturing process.
- To replace traditional welding methods with a more efficient forging technique.
Main Methods:
- Numerical modeling and simulations using Forge 3NxT software.
- Development of a thermo-mechanical model for the forging process.
- Design and fabrication of specialized forging tools and flanging instruments.
Main Results:
- Optimized forging tool designs ensuring proper material flow and impression filling.
- Accurate prediction of temperature and plastic deformation distributions, identifying potential defects.
- Successful industrial trials validating the technology through 3D scanning and hardness testing.
Conclusions:
- The developed hot die forging technology is viable for industrial implementation.
- The process enables efficient production of belt conveyor flights with reduced waste.
- Integration of robotization and automation is feasible, enhancing manufacturing capabilities.
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