Implementation of an open-die forging process for large hollow shafts for wind power plants with respect to an optimized microstructure
To realize large wind power plants in an economically feasible way, it is necessary to identify potential for lightweight design of the generator hollow-shafts, which are commonly produced by casting. The weight of these shafts can significantly be reduced by producing them by open-die forging, since the forming of the material leads to a higher strength, which allows to reduce the wall thickness noticeable. This paper describes the development and implementation of a forging process for hollow shafts with respect to an optimized microstructure. To numerically investigate this process, a realistic finite element simulation model was developed in a first step. The kinematic of the tools has been implemented authentically to provide a realistic material flow and process conditions. Additionally, a material model for the steel 42CrMo4 was integrated into the simulation model to predict the resulting microstructure. Using the implemented FE model, the forging process was optimized manually to achieve a homogeneous and fine-grained microstructure. The optimization was based upon a variation of different forging parameters and the sequence of forging steps. In the next step, a forging on laboratorial scale was performed to validate the simulation model. For this purpose, after forging, specimens from the hollow shaft were evaluated by metallography to determine the final grain size. A comparison of the results with the numerical simulation showed a general agreement of the measured grain size with the numerically calculated grain size. Based upon these results, the process model was transferred to an FE model with an industrial scale. By this it was possible to analyze the transferability of the used FE model regarding the assumptions about the kinematics and the sequence of the forging steps. A numerical investigation of the industrial process proved the scalability of the process to an industrial relevant geometry.
Austenite Grain Growth Behavior of AISI 4140 Alloy Steel
AISI 4140 alloy steel is widely applied in the manufacture of various parts such as gears, rams, and spindles due to its good performance of strength, toughness, and wear resistance. The former researches most focused on its deformation and recrystallization behaviors under high temperature. However, the evolution laws of austenite grain growth were rarely studied. This behavior also plays an important role in the mechanical properties of parts made of this steel. In this study, samples are heated to a certain temperature of 1073 K, 1173 K, 1273 K, and 1373 K at a heating rate of 5 K per second and hold for different times of 0 s, 120 s, 240 s, 360 s, and 480 s before being quenched with water. The experimental results suggest that the austenite grains enlarge with increasing temperature and holding time. A mathematical model and an application developed in Matlab environment are established on the basis of previous works and experimental results to predict austenite grains size in hot deformation processes. The predicted results are in good agreement with experimental results which indicates that the model and the application are reliable.
Rational Design, Synthesis and Evaluation of γ-CD-Containing Cross-Linked Polyvinyl Alcohol Hydrogel as a Prednisone Delivery Platform
This study describes the in-silico rational design, synthesis and evaluation of cross-linked polyvinyl alcohol hydrogels containing γ-cyclodextrin (γ-CDHSAs) as platforms for the sustained release of prednisone (PDN). Through in-silico studies using semi-empirical quantum mechanical calculations, the effectiveness of 20 dicarboxylic acids to generate a specific cross-linked hydrogel capable of supporting different amounts of γ-cyclodextrin (γ-CD) was evaluated. According to the interaction energies calculated with the in-silico studies, the hydrogel made from PVA cross-linked with succinic acids (SA) was shown to be the best candidate for containing γ-CD. Later, molecular dynamics simulation studies were performed in order to evaluate the intermolecular interactions between PDN and three cross-linked hydrogel formulations with different proportions of γ-CD (2.44%, 4.76% and 9.1%). These three cross-linked hydrogels were synthesized and characterized. The loading and the subsequent release of PDN from the hydrogels were investigated. The in-silico and experimental results showed that the interaction between PDN and γ-CDHSA was mainly produced with the γ-CDs linked to the hydrogels. Thus, the unique structures and properties of γ-CDHSA demonstrated an interesting multiphasic profile that could be utilized as a promising drug carrier for controlled, sustained and localized release of PDN.