Richard Douglas, David Kuhlmann, Guidelines for precision hot forging with appli

cations, Journal of Materials Processing Technology, Volume 98, Issue 2, 29 Janu

ary 2000, Pages 182-188, ISSN 0924-0136, DOI: 10.1016/S0924-0136(99)00197-1.
(http://www.sciencedirect.com/science/article/B6TGJ-3YC0F0R-B/2/1779ef1b612a1b1e
d60c929228820d40)
Abstract:
The economic pressures from alternative processes, international competition and
government regulation have made precision hot forging an attractive option for
the forging industry. The forging process is exceedingly complex with many varia
bles. However, new tools have made it possible to simulate and control the forgi
ng process to a degree not thought possible in the past. As a result, we believe
it is now possible to produce highly accurate forgings that were once achievabl
e only by cold forging.
Keywords: Precision forging; Hot forging; Gear forging; Accuracy; Variables
B.-A. Behrens, E. Doege, S. Reinsch, K. Telkamp, H. Daehndel, A. Specker, Precis
ion forging processes for high-duty automotive components, Journal of Materials
Processing Technology, Volume 185, Issues 1-3, ICAMT 2004 (Malaysia) & CCAMT 200
4 (India) Special Issue, 30 April 2007, Pages 139-146, ISSN 0924-0136, DOI: 10.1
016/j.jmatprotec.2006.03.132.
(http://www.sciencedirect.com/science/article/B6TGJ-4K71666-2/2/eb4f10ca7fee467a
180879b07205ad10)
Abstract:
Precision forging is defined as a flashless near net-shape forging operation whi
ch generates high quality parts concerning surface quality and dimensional accur
acy. In the past, precision forging processes have been industrially established
for axis-symmetric parts, e.g. gearwheels and steering pinions. Further develop
ment of the technology to more complex parts, e.g. helical gears, connecting rod
s and crankshafts is expected to lead to a wider implementation into industry. I
n particular high-duty automotive components offer a wide application field for
the precision forging technology. Advantages like shortened production cycles wh
ich are achieved by eliminating machining operations and the saving of raw mater
ial contribute to the ongoing cost-saving trend in the automobile industry. The
design process for complex precision forged parts has to be purpose-built to con
sider the distinctions of this technique. This article describes the adopted met
hods and development process of a precision forging process exemplarily consider
ing a helical gearwheel and a crankshaft.
Keywords: Precision forging; Crankshaft; Gearwheel; Production process
D. B. Shan, W. C. Xu, Y. Lu, Study on precision forging technology for a complex
-shaped light alloy forging, Journal of Materials Processing Technology, Volume
151, Issues 1-3, Special Volume dedicated to Professor Z.R. Wang on the occasion
of his 70th Birthday., 1 September 2004, Pages 289-293, ISSN 0924-0136, DOI: 10
.1016/j.jmatprotec.2004.04.075.
(http://www.sciencedirect.com/science/article/B6TGJ-4D3B307-6/2/f0c878386b3cbc45
39a9fd81fba855e3)
Abstract:
This paper mainly describes the key problems in the precision forging of large a
nd complex-shaped light alloy components. By means of a developed technique, sev
eral magnesium alloy and aluminum alloy forgings have been produced successfully
. Due to the different shapes of the forgings, a scheme of isothermal forming an
d the use of a female die has been adopted and a method in which plastic mats ex
erting die-locking pressure are used, has been proposed. According to the geomet
ric shape and size of the forgings, local loading techniques and diffluence theo
ry have been employed, which can effectively reduce the forging pressure, improv
e the die filling capacity and ensure the manufacture of high quality forgings.
Keywords: Complex-shape forging; Isothermal precision forging; Fully enclosed di
e forging; Combined female die; Local loading
Debin Shan, Xu Yi, Lu Yan, Three-dimensional rigid-plastic finite-element analys
is of the isothermal precision forging of a cylindrical housing, Journal of Mate
rials Processing Technology, Volume 102, Issues 1-3, 15 May 2000, Pages 188-192,
ISSN 0924-0136, DOI: 10.1016/S0924-0136(00)00493-3.
(http://www.sciencedirect.com/science/article/B6TGJ-403W3B5-11/2/504487d21301c3d
bde70fc79955e3018)
Abstract:
An aluminium alloy cylindrical housing, a key component of a helicopter, has suc
h complex geometry that its forming and die design are difficult. In this paper,
a three-dimensional rigid-plastic finite element simulation program has been de
veloped to analyse the forming process of the cylindrical housing. The technolog
ical conditions of isothermal precision forging are established and forging qual
ity is improved according to the above results.
Keywords: Finite element analysis; Cylindrical housing; Isothermal precision for
ging
J.J. Park, H.S. Hwang, Preform design for precision forging of an asymmetric rib
-web type component, Journal of Materials Processing Technology, Volumes 187-188
, 3rd International Conference on Advanced Forming and Die Manufacturing Technol
ogy, 12 June 2007, Pages 595-599, ISSN 0924-0136, DOI: 10.1016/j.jmatprotec.2006
.11.034.
(http://www.sciencedirect.com/science/article/B6TGJ-4MR7D70-3/2/de01fd5b76e9001a
fdf71344a5fa5863)
Abstract:
Rib-web type aerospace and aircraft components in general have small fillet and
corner radii with zero draft angles. In precision forging of such a component, t
he preform should be designed with a great care in order to produce appropriate
metal flows. An improper preform invokes defects of underfilling and folding in
the component with excessive stresses and wears in the forging equipments and di
es. In the present study, it was attempted to design the preform for precision f
orging of an asymmetric rib-web component by predicting metal flows with the rig
id-plastic finite element analysis. It was found that the key to the preform des
ign is a proper distribution of the material, which was successfully achieved by
a thorough investigation of metal flow and volume change from the result of the
finite element analysis.
Keywords: Precision forging; Rib-web component; Preform; FEM; Metal flow
O. Eyercioglu, M.A. Kutuk, N.F. Yilmaz, Shrink fit design for precision gear for
ging dies, Journal of Materials Processing Technology, Volume 209, Issue 4, 19 F
ebruary 2009, Pages 2186-2194, ISSN 0924-0136, DOI: 10.1016/j.jmatprotec.2008.05
.016.
(http://www.sciencedirect.com/science/article/B6TGJ-4SHVSTX-2/2/eaf08015d5679c31
1a9572a3d36eddb6)
Abstract:
The usual way to shrink fit design for precision forging of gear dies is to use
thick wall cylinder theory (analytical approach) assuming that bore diameter is
equal to pitch diameter by neglecting actual gear tooth shape. For more accurate
determination, finite element method (FEM) can be used. The actual stresses pre
dicted by FEM are much higher than the analytical approach, so that the design o
f the gear shaped die is beyond the capability of the analytical approach. In th
is paper, analytical approach for dies with gear teeth is modified using FEM sol
ution sets. FEM analyses results are verified by experiments. During experiments
cylinder approach is observed to be inadequate for forging loads. An easy to us
e set of formula and nomograms for determination of sizes of die and ring, and r
adial interference are presented. The solution set is verified with experiments.
Proposed equations can safely be used for shrink fit design of precision forgin
g gear dies.
Keywords: Gear forging; Die; Shrink fit; Finite element method (FEM)
Hyoji Yoshimura, Katsuhisa Tanaka, Precision forging of aluminum and steel, Jour
nal of Materials Processing Technology, Volume 98, Issue 2, 29 January 2000, Pag
es 196-204, ISSN 0924-0136, DOI: 10.1016/S0924-0136(99)00199-5.
(http://www.sciencedirect.com/science/article/B6TGJ-3YC0F0R-D/2/fd46c458b6570dec
c22e49610062ee4b)
Abstract:
Outline of an enclosed die forging equipment is introduced first. Then some net
shape forming examples of steel and aluminum alloys are enumerated. The possibil
ity of enclosed die forging is discussed finally.
Keywords: Enclosed die forging; Net shape forging; Air compressor scrolls
Soo-Young Kim, Satoshi Kubota, Masahito Yamanaka, Application of CAE in cold for
ging and heat treatment processes for manufacturing of precision helical gear pa
rt, Journal of Materials Processing Technology, Volume 201, Issues 1-3, 10th Int
ernational Conference on Advances in Materials and Processing Technologies - AMP
T 2007, 26 May 2008, Pages 25-31, ISSN 0924-0136, DOI: 10.1016/j.jmatprotec.2007
.11.219.
(http://www.sciencedirect.com/science/article/B6TGJ-4R8MDMV-10/2/156b385c5b0e374
ed12c76683b65da6d)
Abstract:
In this study, numerical simulations, using the general-purpose process simulati
on software DEFORM-3D/HT, were carried out for the design of the cold forged pre
cision helical gear used for the automotive steering part. The helical gear forg
ing was carried out using the designed die set. From the simulation results, for
ming load, normal pressure, effective strain distributions on the workpiece, and
stress distributions on forging dies were investigated. The predicted workpiece
geometry showed good agreement with experimental result. Also, the heat treatme
nt processes of the forged helical gear parts were simulated and compared with t
he experimental results. Highly accurate heat transfer coefficients considering
the complex boundary heat transfer were applied in the current simulations to im
prove the simulation accuracy. The inverse calculation technique was used to fin
d out the accurate heat transfer coefficients to minimize the difference between
simulation and experiment. From the simulation result, the microstructure distr
ibution and geometrical change of teeth were investigated for various quenching
media, such as oil, water, and polymer.
Keywords: Cold forging; Helical gear; Heat treatment simulation; DEFORM
X. Chen, R. Balendra, Y. Qin, A new approach for the optimisation of the shrink-
fitting of cold-forging dies, Journal of Materials Processing Technology, Volume
145, Issue 2, The Manufacturing Engineering Research Centre, 15 January 2004, P
ages 215-223, ISSN 0924-0136, DOI: 10.1016/S0924-0136(03)00672-1.
(http://www.sciencedirect.com/science/article/B6TGJ-496FW87-6/2/7cb3ee3ef8e49eaa
841f8fa95ca4cc7b)
Abstract:
Nett-shape manufacturing of engineering components is a major objective of moder
n material-conversion industries: relevant technologies depend on tools in which
error-compensation can be effected. A novel die-design approach, known as the l
east squares approach, to minimise the component errors is presented. Shrink-fit
ting compensating die structure is employed. The errors caused by die-elasticity
, secondary yielding, springback and temperature are considered in the process o
f minimisation. The main factors that may influence the accuracy of the optimisa
tion procedure are analysed. The final component errors can be controlled to wit
hin a few micrometers. The approach is illustrated using axisymmetric closed-die
forging.
Keywords: Precision-forging; Cold forging; Die/tool design; Design optimisation
Steffen Reinsch, Bernd Mussig, Bernd Schmidt, Kirsten Tracht, Advanced manufactu
ring system for forging products, Journal of Materials Processing Technology, Vo
lume 138, Issues 1-3, IMCC2000, 20 July 2003, Pages 16-21, ISSN 0924-0136, DOI:
10.1016/S0924-0136(03)00033-5.
(http://www.sciencedirect.com/science/article/B6TGJ-48327YR-7/2/89f8ce0176abf9e8
5adf165a86c38792)
Abstract:
The demand of the industry for high quality parts that are provided with a high-
level delivery performance is constantly growing. For increasing the product qua
lity without raising the cost in many cases new processes have to be introduced.
For providing those products flexible and responsive to the market advanced man
ufacturing systems need to be introduced to quickly and reliably deliver to cust
omers in-time.
Using precision forging combined with an advanced manufacturing system for forgi
ng parts that used to be forged traditionally requires changes in the design of
products and processes. Not only the different stages need to be formed with a h
igh precision, the positioning of the inserted parts in the tool needs to be per
formed with a high-level of accuracy as well. In the best-case this is done with
an automated positioning gear. For gaining flexibility the tools are supposed t
o be replaced quickly by a changing system as well.
Besides a flexible and automated forging line for the production of precision fo
rging parts, a high-performance production management system is required that is
specifically tailored to the individual requirements of the advanced manufactur
ing system for precision forging. Therefore a bi-directional integration of the
software modules tool management, production planning and material management ne
eds to be realized.
It is essential for the precision forging process to monitor a number of process
data which can be processed by the production management system. This facilitat
es the linkage of technical process data to logistical data of the product manag
ement system to increase the logistical performance concerning efficiency, lead-
time and in-time delivery of the advanced manufacturing system.
Keywords: Advanced manufacturing system; Flexible forging line; Integrated produ
ction management
J. Cai, T. A. Dean, Z. M. Hu, Alternative die designs in net-shape forging of ge
ars, Journal of Materials Processing Technology, Volume 150, Issues 1-2, 1 July
2004, Pages 48-55, ISSN 0924-0136, DOI: 10.1016/j.jmatprotec.2004.01.019.
(http://www.sciencedirect.com/science/article/B6TGJ-4BWYFX9-3/2/b829b4858bdd08ac
0f775ce5703e3ff3)
Abstract:
This paper deals with the aspects of die design in the gear forging process. It
discusses alternative tool designs which may be used on a press with only one mo
ving slide and ejection system. It examines the influences of different designs
on the metal flow and load requirements through experiments and finite element s
imulation. The effects of friction on the loads and mode of metal flow are discu
ssed.
Keywords: Net-shape; Gear forging; Finite element
Abbas Ghaei, Mohammad R. Movahhedy, Die design for the radial forging process us
ing 3D FEM, Journal of Materials Processing Technology, Volume 182, Issues 1-3,
2 February 2007, Pages 534-539, ISSN 0924-0136, DOI: 10.1016/j.jmatprotec.2006.0
9.013.
(http://www.sciencedirect.com/science/article/B6TGJ-4M6455C-1/2/d1a3bd14ce0c2be9
988c8a685384b4a9)
Abstract:
Radial forging is an open forging process used for reducing the diameters of sha
fts, tubes, stepped shafts and axels, as well as for creating internal profiles
for tubes such as rifling the gun barrels. Most of the previous studies conducte
d on the radial forging process have used axisymmetric models to understand the
effects of die shape on deformation. In order to design a hammer die for radial
forging process, a full 3D model of the process is needed to consider the effect
s of die shape in the cross-section area on deformation. Therefore, the commerci
al finite element code, ABAQUS, was used in this study to model the radial forgi
ng process and the effects of die shape in the cross-section area on deformation
were considered. Additionally, in order to investigate the accuracy of the axis
ymmetric model of the radial forging, the results of 3D FEM model were compared
with those obtained by axisymmetric FEM model.
Keywords: Radial forging; FEM; 3D model; Die design
R.S Lee, J.L Jou, Application of numerical simulation for wear analysis of warm
forging die, Journal of Materials Processing Technology, Volume 140, Issues 1-3,
Proceedings of the 6th Asia Pacific Conference on materials Processing, 22 Sept
ember 2003, Pages 43-48, ISSN 0924-0136, DOI: 10.1016/S0924-0136(03)00723-4.
(http://www.sciencedirect.com/science/article/B6TGJ-498V130-S/2/7b00ea4ced41603b
ec63038b8924a55c)
Abstract:
Warm forging process has better forming precision than hot forging process and h
as better formability than cold forging. But warm forging die sustains higher te
mperature and working pressure, the die wear is faster than those of hot forging
and cold forging. The purpose of this research is to combine the experimental t
echniques, wear model and numerical simulation method to predict the wear of war
m forging die. The non-isothermal ring compression test was adopted to estimate
the friction coefficient in different temperatures and the on-line temperature r
ecording system was setup to correct the heat transfer coefficient of the interf
ace. The wear coefficients in different temperatures were acquired from high tem
perature wear experiment. Finally, the Archard wear theory and DEFORM, a FEM cod
e, were used to analyze the warm forging of automotive transmission outer-race a
nd predict the die wear condition.
Keywords: Warm forging; Ring on disk; Wear coefficient; Numerical simulation; Ve
locity field; Die life
Gyung-Ju Kang, Woo-Jin Song, Jeong Kim, Beom-Soo Kang, Hoon-Jae Park, Numerical
approach to forging process of a gear with inner cam profile using FEM, Journal
of Materials Processing Technology, Volumes 164-165, AMPT/AMME05 Part 2, 15 May
2005, Pages 1212-1217, ISSN 0924-0136, DOI: 10.1016/j.jmatprotec.2005.02.137.
(http://www.sciencedirect.com/science/article/B6TGJ-4FKXGV3-5/2/e8c5204bef596901
6f6705800b443192)
Abstract:
In this paper, numerical approach to cold forging of non-axisymmetric part, slee
ve cam, using FEM combined with equivalent area mapping method is presented. The
mechanical element dealt with numerical analysis in this paper is a component o
f automobile starter motor assembly, which is featured gear tooth outside and ca
m profile inside. Since forging simulation of the whole part is tremendous due t
o non-axisymmetric cam profile with respect to outer tooth, a finite element mod
el for the tooth analysis based on the equivalent area mapping method, is constr
ucted. The method implies that the actual complicated profile is simply fitted b
y an arc with appropriate radius, which makes approximated area and original one
the same. With the proposed finite element model, forging simulation for symmet
ric part of the approximated sleeve cam was carried out. Finally, by comparison
with experimental results, it is shown that the numerical approach proposed in t
his study can successfully predict the strain distribution and metal flow of non
-axisymmetric forged part.
Keywords: FEM; Equivalent area mapping method; Cold forging; Sleeve cam; Gear
Young-Seon Lee, Jung-Hwan Lee, Jong-Ung Choi, T. Ishikawa, Experimental and anal
ytical evaluation for elastic deformation behaviors of cold forging tool, Journa
l of Materials Processing Technology, Volume 127, Issue 1, 20 September 2002, Pa
ges 73-82, ISSN 0924-0136, DOI: 10.1016/S0924-0136(02)00268-6.
(http://www.sciencedirect.com/science/article/B6TGJ-45YG7N8-6/2/af9c1275c768e4e8
20d42440d85b854b)
Abstract:
Since the dimensional accuracy of forged parts are largely influenced by elastic
behaviors of the tool material. The characteristics of elastic deformation at a
forming tool are evaluated for a cold forged alloyed steel by experiment and FE
M analysis.
Elastic strain at the tool is measured dynamically using strain gauges attached
to the surface of die for a ball stud mass-produced continuously in a cold forme
r. Results of FEM analysis are compared to the experimentally measured values at
two modeling approaches. The first approach is made by regarding the die as a r
igid body at a forging cycle and analyzed the die stress by loading the die with
the pressure from the deformed part. On the other hand, the second approach is
adopted as that the die and workpiece are simultaneously considered as deformabl
e bodies during contact. Since calculation of the elastic strain and deformation
amount of tool can be made at each formation step by the second approach, the e
lastic deflection of die acts upon the dimension of forged part at each formatio
n step. The second approach relatively takes more time for the simulation. Howev
er, the analysis result at the elastic assumption of tool is better for predicti
ng not only the elastic strain of tool but also the dimensional accuracy of forg
ed part.
Keywords: Strain gauge; Cold forging; Elastic deformation; FEM; Elastic; Rigid;
Component accuracy
J.H. Kang, K.O. Lee, J.S. Je, S.S. Kang, Spur gear forging tool manufacturing me
thod considering elastic deformation due to shrink fitting, Journal of Materials
Processing Technology, Volumes 187-188, 3rd International Conference on Advance
d Forming and Die Manufacturing Technology, 12 June 2007, Pages 14-18, ISSN 0924
-0136, DOI: 10.1016/j.jmatprotec.2006.11.161.
(http://www.sciencedirect.com/science/article/B6TGJ-4MS9R4Y-6/2/74cb01e667d9a715
feffc41833984a0d)
Abstract:
This research introduces an advanced manufacturing method for gear part tools. I
n the conventional method, wire cutting and lapping of the corner region were pe
rformed after shrink fitting to ensure the accuracy of the gear profile. But lap
ping is difficult when the corner region is located inside of the die. The new t
ool manufacturing method suggests that wire cutting and lapping are performed af
ter the 1st shrink fitting to facilitate lapping operation and to increase the a
ccuracy of the corner radius. Finite element analysis and forging test are perfo
rmed. Comparison between analysis and measurement of forged part ensures the val
idity of suggested tool manufacturing methods.
Keywords: Gear forging; Cold forging; Elastic deformation; Shrink fitting; Finit
e element analysis
D. J. Jeong, D. J. Kim, J. H. Kim, B. M. Kim, T. A. Dean, Effects of surface tre
atments and lubricants for warm forging die life, Journal of Materials Processin
g Technology, Volume 113, Issues 1-3, 15 June 2001, Pages 544-550, ISSN 0924-013
6, DOI: 10.1016/S0924-0136(01)00693-8.
(http://www.sciencedirect.com/science/article/B6TGJ-435KP5X-38/2/c72506cd88bdf7f
0802a0b5fef4dd3a0)
Abstract:
In most metal forming applications, the surface treatments and lubricants are th
e main factors influencing die life, since they directly determine the interface
friction and thermal insulation. In general, in hot and warm forging processes,
the surface hardness of the die is decreased while the temperature of the die i
ncreased during repeated operations, which induce thermal softening. The thermal
softening causes the plastic deformation of die despite the forming load not be
ing changed. In this study, experiments and numerical analyses were performed un
der various conditions: two kinds of surface treatment, two lubricants, differen
t initial billet temperatures and different loads; to investigate the effects on
thermal softening and the amount of heat-transfer. Carbon nitride (CNx), ion-ni
tride and no surface treatment for the dies were used and oil-based and water-ba
sed graphite were used as lubricants. Experiments were also performed to take th
e heat-transfer coefficient into account with the combination of surface treatme
nts and lubricants. The coefficients determined were then used in a finite eleme
nt model for the analysis of the backward extrusion process, the results produce
d were compared being experiment.
Keywords: Warm forging; Thermal softening; Heat-transfer; Carbon nitride; Ion-ni
tride; Lubricant; Graphite; Die life
K.S. Park, Chester J. VanTyne, Y.H. Moon, Process analysis of multistage forging
by using finite element method, Journal of Materials Processing Technology, Vol
umes 187-188, 3rd International Conference on Advanced Forming and Die Manufactu
ring Technology, 12 June 2007, Pages 586-590, ISSN 0924-0136, DOI: 10.1016/j.jma
tprotec.2006.11.036.
(http://www.sciencedirect.com/science/article/B6TGJ-4MSR8MW-2/2/147c1ab993c9346f
ab43166eeb345376)
Abstract:
Much progress in forging technology including low production cost and fast produ
ction has allowed an intensive use of forging. Manufacturing companies have espe
cially focused on producing a complex shaped part with a tight dimensional toler
ance. Traditional warm and cold forging methods have their own limitations to pr
oduce such a complex shaped part; warm forging requires complex system with rela
tively higher manufacturing cost, while cold forging is not applicable to materi
als with limited formability. Therefore, multistage forging may be advantageous
to produce complex shaped parts. In order to build a multistage forging system,
it is necessary to characterize mechanical properties in response to system desi
gn parameters such as temperature, forging speed and reduction. For the analysis
of formability of multistage forging process, finite element method (FEM) has b
een used for the process analysis. As a model case, a constant velocity (CV) joi
nt forging process is analyzed by FEM, since CV joint has a complex shape and al
so its required dimensional tolerances are very tight. A systematic approach to
process analysis is established using the FEM for the multistage forging of the
CV joint outer race.
Keywords: Finite element method; Multistage forging; CV joint; Outer race; Ball
groove
A.K. Sahoo, M.K. Tiwari, A.R. Mileham, Six Sigma based approach to optimize radi
al forging operation variables, Journal of Materials Processing Technology, Volu
me 202, Issues 1-3, 20 June 2008, Pages 125-136, ISSN 0924-0136, DOI: 10.1016/j.
jmatprotec.2007.08.085.
(http://www.sciencedirect.com/science/article/B6TGJ-4R0CK3C-1/2/4e2e8dba773a3778
921b9a4b4882d91c)
Abstract:
The present competitive market is focusing industrial efforts on producing high-
quality products with the lowest possible cost. To help accomplish this objectiv
e, various quality improvement philosophies have been put forward in recent year
s and of these Six Sigma has emerged as perhaps the most viable and efficient te
chnique for process quality improvement. The work in this paper focuses on imple
menting the DMAIC (Define, Measurement, Analyze, Improve, and Control) based Six
Sigma approach in order to optimize the radial forging operation variables. In
this research, the authors have kept their prime focus on minimizing the residua
l stress developed in components manufactured by the radial forging process. Ana
lysis of various critical process parameters and the interaction among them was
carried out with the help of Taguchi's method of experimental design. To optimiz
e the results obtained and to make the analysis more precise and cost effective,
response surface methodology (RSM) was also incorporated. The optimized paramet
ers obtained using Taguchi method and RSM were then tested in an industrial case
study and a trade-off made to finalize the recommended process parameters used
in manufacture.
Keywords: Six Sigma; Orthogonal array; Response surface methodology; Radial forg
ing; Design of experiment (DOE); S/N ratio; Analysis of variance (ANOVA)
Conor MacCormack, John Monaghan, Failure analysis of cold forging dies using FEA
, Journal of Materials Processing Technology, Volume 117, Issues 1-2, 2 November
2001, Pages 209-215, ISSN 0924-0136, DOI: 10.1016/S0924-0136(01)01139-6.
(http://www.sciencedirect.com/science/article/B6TGJ-44B4XX4-10/2/d7484d9a5b8f68f
a4cc7e46d656e0957)
Abstract:
The results presented within this paper represent part of a larger collaborated
investigation being conducted by Trinity College, Dublin and an industrial partn
er. The particular cold forging process analysed was the method used to `trim' a
hexagonal shape on the head of a fastener. The fastener head geometry is achiev
ed by forcing the die, known as a trim die because of its function, onto the wor
kpiece, whereupon a combined forging and cutting action produces the desired wel
l-known hexagonal shape for the head. The size of the trim die modelled was that
for an M6 fastener. The trim die material was taken as M2 high-speed steel.
When the trim die reaches the end of its stroke, a knockout pin shears off the e
xcess trimmed material. A finite element analysis package called DEFORM(c) was i
mplemented to simulate the trim die forging process. DEFORM utilises Cockroft an
d Latham's fracture criteria to calculate the damage induced within the workpiec
e material during the process. Elements are deleted from the model when they exc
eed a specified damage value. The trim die geometry, if incorrect, can cause pre
mature shearing of the waste material during forging. This premature shearing ha
s a detrimental effect on tool life and the forging machinery. The relationship
between the trim die geometry and its final stopping distance, the consequent in
duced stresses and the energy required to shear off this excess material was inv
estigated. Finally the effect of altering the damage value C was analysed, see E
q. (1). From this investigation, conclusions as to the optimum trim die shape an
d final stopping distance, which would facilitate increased die life, were obtai
ned.
Keywords: Trim die; Cold forging; Finite element analysis; DEFORM; Fracture
Gangshu Shen, David Furrer, Manufacturing of aerospace forgings, Journal of Mate
rials Processing Technology, Volume 98, Issue 2, 29 January 2000, Pages 189-195,
ISSN 0924-0136, DOI: 10.1016/S0924-0136(99)00198-3.
(http://www.sciencedirect.com/science/article/B6TGJ-3YC0F0R-C/2/87236a73fd2676da
5ca44e4d8963ff46)
Abstract:
Advanced forging and heat treatment methods with enhanced material technology an
d computer modeling techniques are key elements for the success of modern forgin
g processes used in the aerospace forging sector. Modern forging, heat treating
and process design methods are being developed to further enhance the state of t
he art of manufacturing aerospace forgings. Improved processes, equipment and co
mputer modeling tools are building on each other to rapidly advance the manner i
n which aerospace forging methods are designed and implemented, resulting in red
uced development times, improved metal utilization, and reduced component costs.
Keywords: Aerospace forging; Computer modeling
Hyunkee Kim, Tetsuji Yagi, Masahito Yamanaka, FE simulation as a must tool in co
ld/warm forging process and tool design, Journal of Materials Processing Technol
ogy, Volume 98, Issue 2, 29 January 2000, Pages 143-149, ISSN 0924-0136, DOI: 10
.1016/S0924-0136(99)00190-9.
(http://www.sciencedirect.com/science/article/B6TGJ-3YC0F0R-3/2/f9618a1f9294d0d5
34e9ea9f0eb7c370)
Abstract:
This paper describes the brief history and the current status of practical use o
f FE simulations with examples. Key points for practical use of FE simulation as
a daily work tool in forging area is also discussed followed by future approach
es for more effective use of the FE simulation.
Keywords: FE simulation; Practical use; Cold/warm forging; Process design; Tool
design
W.S. Weronski, A. Gontarz, Z. Pater, The research of forging process of eccentri
c part on three slide forging press, Journal of Materials Processing Technology,
Volume 177, Issues 1-3, Proceedings of the 11th International Conference on Met
al Forming 2006, 3 July 2006, Pages 214-217, ISSN 0924-0136, DOI: 10.1016/j.jmat
protec.2006.03.203.
(http://www.sciencedirect.com/science/article/B6TGJ-4K4WMR2-6/2/b88f1fdb939d09ce
536698a4cdd705b7)
Abstract:
In this paper the results of theoretical and experimental tests of eccentric par
t forming on a three slide forging press (TSFP) are presented. The application o
f tools with a recess in the lower clamping dies results in asymmetric material
flow during upsetting which causes the eccentric forming. Theoretical analyses o
f this process were made with the application of 3D FEM simulation. Based on the
oretical results, it was stated that the eccentricity e depends on length L and
angle [alpha] of the recess in the lower clamping dies. The area of process stab
ility is limited by the absence of eccentricity (with low [alpha] and L values)
and the presence of overlaps (in the case of [alpha] and L being too large). The
theoretical dependence between eccentricity value e and tool geometry parameter
s L and [alpha] was obtained. The experimental tests confirmed a good agreement
between theoretical and experimental results.
Keywords: Eccentric shaft; Three slide forging press; FEM simulation
Jongung Choi, Hae-Young Cho, Chang-Yong Jo, Forging of spur gears with internal
serrations and design of the dies, Journal of Materials Processing Technology, V
olume 104, Issues 1-2, 18 August 2000, Pages 1-7, ISSN 0924-0136, DOI: 10.1016/S
0924-0136(00)00523-9.
(http://www.sciencedirect.com/science/article/B6TGJ-4106981-M/2/139fd6539dbba7a9
35874d57fc47ef17)
Abstract:
Numerical calculation tools based on the upper-bound method, which could be used
in the forging of gear-like components having various deformation features, are
suggested. The numerical calculation tools can calculate both the internal and
external flow of metal within dies, such as an external involute spur gear, a sq
uare spline and internal serrations. A complex calculation tool for the forging
of gear-like components has been developed by combining these calculation tools.
The workpiece, which has external and internal teeth, was divided into two bloc
ks. The deformation of the two blocks was also analyzed by testing the numerical
calculation tool, which was derived from a kinematically admissible velocity fi
eld. Experimental inspection was carried out with a 200 t hydraulic press, the r
esults showing good agreement with the calculated solution. Therefore, the calcu
lation tool could be useful to predict the capacity of a forging facility and in
the design of dies.
Keywords: Spur gear; Square spline; Internal serrations
M. Skunca, P. Skakun, Z. Keran, L. Sidjanin, M.D. Math, Relations between numeri
cal simulation and experiment in closed die forging of a gear, Journal of Materi
als Processing Technology, Volume 177, Issues 1-3, Proceedings of the 11th Inter
national Conference on Metal Forming 2006, 3 July 2006, Pages 256-260, ISSN 0924
-0136, DOI: 10.1016/j.jmatprotec.2006.04.061.
(http://www.sciencedirect.com/science/article/B6TGJ-4K9C58P-7/2/68c0ace4a9964767
22bebec1b375104d)
Abstract:
The improvement of specific metal forming technologies, nowadays includes the us
e of numerical program packages. One such technology is the radial extrusion of
gears and gear-like components in the cold state. This technology is known for i
ts high productivity, achievable high specific strength and low cost per part pr
oduced. Improvements of such high technology products can be only achieved by th
e detailed numerical analysis. Since there is a large number of programs availab
le, it is necessary to carry out the comparisons between the experiment and simu
lation. One of the commonly used methods is the comparison of experimentally and
numerically obtained load-displacement diagrams. Although significant, good acc
ordance of such load-displacement diagrams is insufficient proof of having a goo
d numerical model. In this paper an additional, non-conventional method is used
to assess the strain distribution within the workpiece. Though the experimentall
y obtained strain field was used as a reference, the numerically obtained strain
 distribution pointed to the highly stressed points, giving a direction to the f
urther experimental examination of strain distribution in greater detail. The re
sult is an improvement of both experiment and numerical model. In the simulation
there are inherent non-linearities coming from geometry, strain hardening and f
riction. In the determination of the strain distribution, a very complex phenome
non of restoration was used. The combination resulted in a model of the radial e
xtrusion that can be used in numerical simulations of similar metal forming proc
esses.
Keywords: Radial gear extrusion; Numerical simulation; Finite elements method
B. P. Bewlay, M. F. X. Gigliotti, C. U. Hardwicke, O. A. Kaibyshev, F. Z. Utyash
ev, G. A. Salischev, Net-shape manufacturing of aircraft engine disks by roll fo
rming and hot die forging, Journal of Materials Processing Technology, Volume 13
5, Issues 2-3, Special Issue containing paper from the conference @'Research and
, 20 April 2003, Pages 324-329, ISSN 0924-0136, DOI: 10.1016/S0924-0136(02)00864
-6.
(http://www.sciencedirect.com/science/article/B6TGJ-478RR0C-3/2/64833a0bfe2c95cb
638765127094a901)
Abstract:
Roll forming is a novel technique for manufacturing aircraft engine turbine disk
s. This paper describes an assessment of the technical and economic viability of
roll forming. The capabilities of roll forming will also be compared to those o
f hot die forging. It was found that there is an economic pay-off for roll formi
ng complex, low production-volume parts of nickel and titanium alloys due to a h
igher material yield and less expensive tooling. Roll formed disks of high tempe
rature nickel and titanium alloys were evaluated for dimensional control, metall
urgical structure, mechanical properties, and ultrasonic characteristics. The re
sults from complex shapes indicate that disks can be produced with uniform micro
structures and excellent properties. The roll formed titanium disks possessed [a
lpha]-[beta]-Ti microstructures with a mean grain size of 5-10 [mu]m. Electron b
ack-scattering pattern analysis and inverse pole figure analyses indicated that
the disks possessed essentially no crystallographic texture. Samples machined fr
om axial, radial, and tangential sections of disks were tested in order to evalu
ate any anisotropy in mechanical properties of the disks.
Keywords: Roll forming; Nickel; Titanium; Economic analysis; Complex shapes
L.M. Alves, P.A.F. Martins, Flexible forming tool concept for producing cranksha
fts, Journal of Materials Processing Technology, Volume 211, Issue 3, 1 March 20
11, Pages 467-474, ISSN 0924-0136, DOI: 10.1016/j.jmatprotec.2010.10.024.
(http://www.sciencedirect.com/science/article/B6TGJ-51D15TR-7/2/7f0af38b64bb1a64
6102c35d99a90792)
Abstract:
Forging, casting and machining compete on quality and price for the production o
f crankshafts. Forging and casting are commonly utilized for mass production bec
ause the capital investment in equipment and tooling are very high. Machining is
employed only in case of small production batches of high quality crankshafts m
ade from materials that are normally difficult to forge or cast because it is ti
me and energy intensive, generates a lot of waste and is generally more costly t
han forging and casting.
As a result of this, conventional manufacturing routes for crankshafts are not s
uitable for flexible small to medium-batch production and, therefore, are not ap
propriate for the growing agile manufacturing trends requiring very short life-c
ycles and very short development and production lead times.
This paper is concerned with these issues and is focused on the development of a
n innovative forming tool concept for producing small to medium-batches of cost
competitive crankshafts. The proposed tool concept combines knowledge on bucklin
g of solid rods under compression with flexible construction solutions based on
modular dies to allow crankshaft production to change output rapidly. Single cyl
inder to multi cylinder crankshafts including multiple main bearing journals, cr
ankpins and crank webs can be easily produced by fastening or removing appropria
te die modules in the overall tool set.
The presentation is illustrated with test cases obtained from finite element mod
elling and experimentation with a laboratory prototype tool conceived to operate
exclusively with lightweight materials exhibiting high ductility in cold formin
g.
Keywords: Crankshafts; Flexible forming tool; Finite element method; Experimenta
tion