I. Hahn, M. Schneider, MAGMA Giessereitechnologie GmbH, H. Schafstall, C. Barth, Simufact Engineering GmbH, Germany
Many quality problems in forged steel products have their origin in the ingot casting process. Defects like shrinkage, porosity, segregation, non-metallic inclusions and cracks are initiated during teeming of the liquid steel, but their position and severity are also affected by the material flow during forming operations. Process simulation tools for both casting and forming processes are available and used daily for analysing and optimizing the quality and productivity of each process. These two worlds of simulation have only rarely been brought together. There is a clear need for a through-process methodology to predict possible defects and to optimize the whole process chain, such that the best possible quality and the lowest reject rate is obtained. Here, information about the shrinkage cavity, internal porosity and macrosegregation in a cast steel ingot from casting process simulation are transferred as input for the simulation of the subsequent cogging process. The results of the cogging simulation clearly show how the forming process affects the size and shape of the ascast shrinkage and segregation or can show if internal porosity can be closed by material flow.
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