A study on precision cold forging process improvements for the steering yoke of automobiles by the rigid–plastic finite-element method

2003 ◽  
Vol 138 (1-3) ◽  
pp. 339-342 ◽  
Author(s):  
Dong-Kyun Min ◽  
Min-Eung Kim
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cold Forging ◽  
Rigid Plastic ◽  
Process Improvements ◽  
Forging Process ◽  
Element Method

Finite Element Simulation for Forging Process Using Euler’s Fixed Meshing Method

2008 ◽  
Vol 575-578 ◽  
pp. 1139-1144 ◽  
Author(s):  
Chan Chin Wang
Keyword(s):  
Finite Element Method ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Large Deformation ◽  
The Body ◽  
Rigid Plastic ◽  
Element Analysis ◽  
Forging Process ◽  
Deformation Problem ◽  
Element Method

A simulator based on rigid-plastic finite element method is developed for simulating the plastic flow of material in forging processes. In the forging process likes backward extrusion, a workpiece normally undergoes large deformation around the tool corners that causes severe distortion of elements in finite element analysis. Since the distorted elements may induce instability of numerical calculation and divergence of nonlinear solution in finite element analysis, a computational technique of using the Euler’s fixed meshing method is proposed to deal with large deformation problem by replacing the conventional way of applying complicated remeshing schemes when using the Lagrange’s elements. With this method, the initial elements are generated to fix into a specified analytical region with particles implanted as markers to form the body of a workpiece. The particles are allowed to flow between the elements after each deformation step to show the deforming pattern of material. The proposed method is found to be effective in simulating complicated material flow inside die cavity which has many sharp edges, and also the extrusion of relatively slender parts like fins. In this paper, the formulation of rigid-plastic finite element method based on plasticity theory for slightly compressible material is introduced, and the advantages of the proposed method as compared to conventional one are discussed.

scholarly journals Application of Numerical Simulation and Physical Modeling for Verifying a Cold Forging Process for Rotary Sleeves

2021 ◽  
Author(s):  
Tomasz Bulzak ◽  
Grzegorz Winiarski ◽  
Łukasz Wójcik ◽  
Mirosław Szala
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Experimental Tests ◽  
Simulation Software ◽  
Cold Forging ◽  
Work Piece ◽  
Geometrical Parameters ◽  
Forging Process ◽  
Forged Parts ◽  
Element Method

AbstractThis paper presents the modeling of a cold forging process for a rotary sleeve. The process of forging a EN 42CrMo4 steel part was first modeled numerically by the finite element method using simulation software DEFORM 3D ver. 11.0. After that, the developed forging process was verified by experimental tests carried out in laboratory conditions with the use of 1:2 scale tools and a material model of aluminum alloy EN AW-6060. Finite element method (FEM) results demonstrated that rotary sleeves could be formed from tubes by cold forging. Results of the experimental tests showed, however, that the material inside the hole of the work piece might not adhere to the surface of the sizing pin. Distributions of strain and stress during the forging process are determined. Geometrical parameters of forged parts obtained in experimental tests are compliant with the dimensions of forged parts simulated by FEM. In addition, experimental forces of the forging process show a high agreement with the forces obtained in FEM simulations.

Prediction of Temperature Distributions of Cold Forging Process for a CamBolt by FEM

2013 ◽  
Vol 404 ◽  
pp. 207-212
Author(s):  
Dong Bum Kim ◽  
S. Kim ◽  
Jin Gun Park ◽  
Hyuk Soo Shin ◽  
Won Yeong Kim ◽  
...  
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Temperature Distribution ◽  
Endurance Limit ◽  
Steering System ◽  
Cold Forging ◽  
Forging Process ◽  
Temperature Distributions ◽  
A New Technique ◽  
Element Method

Temperature distributions of cold forging process for a cambolt has been predicted by using finite element method in this paper. The cambolt is used as a part in the steering system of a vehicle for the purpose of driving balanced, so some proper mechanical properties such as strength and endurance limit are required for this part. Moreover, temperature is also an important factor to realize mass production and improve efficiency. However, direct measurement of temperature in a forging process is infeasible with existing technology; therefore, there is a critical need for a new technique. In this study, the thermo-coupled finite element method has been presented for predicting the temperature distribution. The rate of the energy conversion to heat for the material of workpiece has been defined and the temperature distribution throughout the forging process of the cambolt has been analyzed. Experimental verification of the technique is presented.

Finite Element Method for Step Reduction in Forming Socket Head Screws

2012 ◽  
Vol 622-623 ◽  
pp. 107-111
Author(s):  
Somkid Thara ◽  
Kusol Prommul ◽  
Bhadpiroon Sresomroeng ◽  
Jiraporn Sripraserd
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Flow Line ◽  
Cold Forging ◽  
Forging Process ◽  
Part Quality ◽  
Die Stress ◽  
The Cost ◽  
Forging Force ◽  
Element Method

Nowadays, step reduction in the manufacturing process is an important issue because it reduces both the cost and time. The objective of this research is to reduce the steps used in the cold forging process of a socket head screw from 3 steps (existing design) to 2 steps (new design). The commercial FEM (Finite Element Method) software was used for simulating the values of flow line, forging force and die stress, which were then used to determine part quality and tool life. The results have shown that the simulated values of 2-step design are similar to 3-step design.

A fast rigid-plastic finite element method for online application in strip rolling

2010 ◽  
Vol 46 (12) ◽  
pp. 1146-1154 ◽  
Author(s):  
S.H. Zhang ◽  
G.L. Zhang ◽  
J.S. Liu ◽  
C.S. Li ◽  
R.B. Mei
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Strip Rolling ◽  
Rigid Plastic ◽  
Online Application ◽  
Element Method

scholarly journals Collision and Crush Penetration Analysis by Rigid Plastic Finite Element Method.

1993 ◽  
Vol 59 (564) ◽  
pp. 1874-1880
Author(s):  
Toshio Tsuta ◽  
Shingo Okamoto ◽  
Tsuyoshi Kobayashi ◽  
Yoshio Miyagawa
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Rigid Plastic ◽  
Element Method

Hot Forging Comparative Analyses by Using a Combined Finite Element Method

2007 ◽  
Vol 340-341 ◽  
pp. 737-742
Author(s):  
Yong Ming Guo
Keyword(s):  
Heat Transfer ◽  
Finite Element Method ◽  
Finite Element ◽  
Hot Forging ◽  
Rigid Plastic ◽  
Numerical Examples ◽  
Comparative Analyses ◽  
Single Action ◽  
Element Method

In this paper, single action die and double action die hot forging problems are analyzed by a combined FEM, which consists of the volumetrically elastic and deviatorically rigid-plastic FEM and the heat transfer FEM. The volumetrically elastic and deviatorically rigid-plastic FEM has some merits in comparison with the conventional rigid-plastic FEMs. Differences of calculated results for the two forging processes can be clearly seen in this paper. It is also verified that these calculated results are similar to those of the conventional rigid-plastic FEM in comparison with analyses of the same numerical examples by the penalty rigid-plastic FEM.

Sign in / Sign up

Export Citation Format

Share Document