Browsing by Author "Hawryluk, Marek"

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Access status: Open Access ,
Capabilities of numerical simulation support for defect investigations in die forgings
(Wydawnictwa AGH, 2024) Hawryluk, Marek; Polak, Sławomir; Dudkiewicz, Łukasz; Marzec, Jan; Jabłońska, Magdalena; Suliga, Maciej; Tkocz, Roger; Korpala, Grzegorz
The article concerns the use of the results of numerical simulations, primarily for the detection of defects in forged products identified at various stages, along with the analysis of the geometry of forgings and the way in which the material flows in tools. The work presents the results of measurements and analyses using numerical modelling based on computational packages dedicated to forging processes such as: QForm, Forge, etc., which are equipped with special functions that significantly facilitate analyses by both technicians and designers. These functions include: contact of the deformed material with the tool, flow line distribution, “trap” or “fold” functions for detecting forging defects, as well as other technological parameters and physical sizes, which are crucial in the case of a comprehensive analysis of the industrial die forging process. The novelty of the work is the presentation of the possibility of simultaneously combining many different non-destructive techniques and methods, e.g. results of FE simulations with 3D reverse scanning, minimizing interference in the industrial process. The research carried out allows for the thorough and rapid analysis of the correctness of the deformation of the forging material for selected forging processes, along with the presentation of methods for their prevention and solving va
Access status: Open Access ,
The application of numerical simulations to analyze the forward extrusion process along with the verification of results and tuning of the numerical model
(Wydawnictwa AGH, 2025) Hawryluk, Marek; Dudkiewicz, Łukasz; Marzec, Jan; Tkocz, Roger; Borowski, Jacek; Ficak, Grzegorz; Jóźwiak, Bartosz; Ziemba, Jacek
The paper presents the application of numerical simulations based on the Finite Element Method (FEM) for analyzing and optimizing the extrusion processes of aluminum and lead. These processes are efficient methods for manufacturing critical machine parts and metal components, ensuring excellent mechanical properties. A detailed analysis was conducted on the numerical modeling of the impact of die taper angles on strain distribution and forming forces during co-extrusion. The study found that a 45-degree angle provides optimal deformation conditions, minimizing extrusion forces and reducing the formation of dead zones compared to a 90-degree angle. Numerical simulations, supplemented by technological trials under semi-industrial conditions and image analysis involving the deformation of the coordinate grid, provided key insights into a material flow, strain distribution, and force parameters. The results emphasize the importance of validating numerical models with semi-industrial experiments to ensure accuracy and reliability, as assuming constant tribological conditions may not reflect actual process conditions, including the formation of dead zones for angles greater than 45°. It was only through a thorough analysis of the actual process and the introduction of variable friction coefficients for individual tools that a dead zone was achieved in the modelling. The findings from this research can serve as the foundation for further optimization and adaptation of technological processes, aiming to further enhance extrusion processes through the use of numerical simulations.