scholarly journals Generalized optimizations of two-stage forging of micro/meso copper fastener

2018 ◽  
Vol 185 ◽  
pp. 00002
Author(s):  
Shih-Hsien Lin ◽  
Un-Chin Chai ◽  
Gow-Yi Tzou ◽  
Dyi-Cheng Chen
Keyword(s):  
Simulation Analysis ◽  
Effective Strain ◽  
Cold Forging ◽  
Two Stage ◽  
Forming Simulation ◽  
Multi Stage ◽  
Element Simulation ◽  
Die Stress ◽  
Stress Optimization ◽  
Forging Force

Three are generalized simulation optimizations considering the forging force, the die stress, and the dual-goals in two-stage forging of micro/meso copper fastener. Constant shear friction between the dies and workpiece is assumed to perform multi-stage cold forging forming simulation analysis, and the Taguchi method with the finite element simulation has been used for mold-and-dies parameters design simulation optimizations considering the forging force, die stress, and dual-goals. The die stress optimization is used to explore the effects on effective stress, effective strain, velocity field, die stress, forging force, and shape of product. The influence rank to forging process of micro/meso copper fastener for three optimizations can be determined, and the optimal parameters assembly consider die stress can be obtained in this study. It is noted that the punch design innovation can reduce the forging force and die stress.

Optimization of Forging Preforms by Using Pseudo Inverse Approach

2012 ◽  
Vol 504-506 ◽  
pp. 613-618 ◽  
Author(s):  
Ali Halouani ◽  
Y.M. Li ◽  
Boussad Abbès ◽  
Y.Q. Guo ◽  
F.J. Meng ◽  
...  
Keyword(s):  
Effective Strain ◽  
Equivalent Stress ◽  
Optimization Method ◽  
Final Part ◽  
Cold Forging ◽  
Inverse Approach ◽  
Multi Stage ◽  
Optimization Loop ◽  
Forging Force ◽  
Pseudo Inverse

A simplified method called “Pseudo Inverse Approach” (PIA) has been developed for axi-symmetrical cold forging modelling. The approach is based on the knowledge of the final part shape. Some intermediate configurations are introduced and corrected by using a free surface method to consider the deformation paths without classical contact treatment. A new direct algorithm of plasticity is developed using the notion of equivalent stress and the tensile curve, which leads to a very fast and robust plastic integration procedure. Numerical tests have shown that the Pseudo Inverse Approach is very fast compared to the incremental approach. In this paper, the PIA will be used in an optimization loop for the preliminary preform design in multi-stage forging processes. The optimization problem is to minimize the effective strain variation in the final part and the maximum forging force during the forging process. The numerical results of the optimization method using the PIA are compared to those using the classical incremental approaches to show the efficiency and limitations of the PIA.

Study on Multi-Stage Cold Forging of Stainless Automotive Battery Fastener

2013 ◽  
Vol 284-287 ◽  
pp. 211-215
Author(s):  
Ming Chao Sun ◽  
Gow Yi Tzou ◽  
Liang An Zheng
Keyword(s):  
Error Rate ◽  
Effective Strain ◽  
Cold Forging ◽  
Fourth Stage ◽  
Future Production ◽  
Multi Stage ◽  
Measurement Results ◽  
The Future ◽  
3D Software ◽  
Forging Force

Stainless automotive battery fastener requires high dimension precision and narrow tolerance. In order to save the developing cost and accumulate more production design experiences, CAD/CAE technology has been used in multi-stage cold forging with five stages to shorten our developing cycle time. In this paper, the CAD drawing is made by Inventor 3D software, then import the STL file to DEFORM-3D software to do the settings of pre-process and simulation analysis. Effective stress, effective strain, velocity field, and forging force have been shown in this study. Finally, the actual manufacture measurement results compares with simulation datum to verify the analysis acceptance. After comparing the FEM simulation results with actual forming measurements, the error rate of washer diameter is increased in fourth stage. Although the measurement results are still in tolerance, the future work is to decrease the error rate through optimizing the mold design of fourth stage. The verification is performed to reduce the error rate according to the research method proposed in the study. On the other hand, the mold life in the actual forming is found to be easily damaged in the fifth stage. In the future, production improvement should be done through modifying the design of mold and die for the third and the fourth stages, the life of mold and die is explored to reduce the forging force in the fifth stage.

scholarly journals Automatic Multi-Stage Cold Forging of an SUS304 Ball-Stud with a Hexagonal Hole at One End

Materials ◽  
2020 ◽  
Vol 13 (22) ◽  
pp. 5300
Author(s):  
Jong Bok Byun ◽  
Mohd Kaswandee Razali ◽  
Chang Ju Lee ◽  
Il Dong Seo ◽  
Wan Jin Chung ◽  
...  
Keyword(s):  
Flow Stress ◽  
Room Temperature ◽  
Cold Forging ◽  
Material Strength ◽  
Element Analysis ◽  
Multi Stage ◽  
Plastic Deformation Behavior ◽  
Die Stress ◽  
Hexagonal Hole ◽  
Good Strain

SUS304 stainless steel is characterized by combined tensile and compression testing, with an emphasis on flow stress at higher strain and temperature. The plastic deformation behavior of SUS304 from room temperature to 400 °C is examined and a general approach is used to express flow stress as a closed-form function of strain, strain rate, and temperature; this is optimal when the strain is high, especially during automatic multi-stage cold forging. The fitted flow stress is subjected to elastothermoviscoplastic finite element analysis (FEA) of an automatic multi-stage cold forging process for an SUS304 ball-stud. The importance of the thermal effect during cold forging, in terms of high material strength and good strain-hardening, is revealed by comparing the forming load, die wear and die stress predictions of non-isothermal and isothermal FEAs. The experiments have shown that the predictions of isothermal FEA are not feasible because of the high predicted effective stress on the weakest part of the die.

Die Stress Optimization Using Finite Element and Taguchi Method

2013 ◽  
Vol 762 ◽  
pp. 319-324 ◽  
Author(s):  
Rajkumar Ohdar ◽  
Md Israr Equbal ◽  
Vinod Kumar
Keyword(s):  
Finite Element ◽  
Taguchi Method ◽  
Billet Temperature ◽  
Forging Process ◽  
Element Simulation ◽  
Die Stress ◽  
Modeling Software ◽  
Stress Optimization ◽  
3D Solid ◽  
3D Software

In this study, finite element simulation and the Taguchi method are employed to optimize the die stress in hot closed die forging process. Investigations are carried out for forging of automotive spring saddle by including all realistic process parameters. The research involved analyzing the effects of flash thickness, billet temperature, die temperature and friction coefficient on effective die stress by means of computer simulation. To obtain the result the forging process was modeled in CATIA V5, 3D Solid Modeling Software, simulated in DEFORMTM 3D Software, and statistically setup and examined using Taguchis orthogonal array. Analysis of variance (ANOVA) is employed to determine significant parameters.

FEM Simulation and Experimental Verification on Rotating Forging of Three-Layer Clad Cylinder Considering Constant Shear Friction

2012 ◽  
Vol 602-604 ◽  
pp. 2214-2218
Author(s):  
Gow Yi Tzou
Keyword(s):  
Finite Element ◽  
Velocity Field ◽  
Effective Strain ◽  
Fem Simulation ◽  
Interface Friction ◽  
Finite Element Software ◽  
Constant Shear ◽  
Element Simulation ◽  
Shear Friction ◽  
Forging Force

This study assumes the interface friction between dies and bounded three-layer clad cylinder as constant shear friction considering the rotation of three-layer bounded clad cylinder to establish the finite element simulation. The commercial finite element software (SUPERFORM) is used to explore effectively the effective stress, effective strain, and velocity field, forging force, and rotating torque in the three-layer clad cylinder rotating forging. Moreover, the rotating forging experiment of the three-layer clad cylinder is carried out practically to measure the forging force and the outer surface of three-layer clad cylinder. Forging force between analysis and experiment are compared to verify the acceptance of FEM simulation. This study can be offered to industries for technology establishment of rotating forging.

FEM Simulation of Multi-Stage Forging for Dray Fasteners

2020 ◽  
Vol 830 ◽  
pp. 1-8 ◽  
Author(s):  
Un Chin Chai ◽  
Gow Yi Tzou ◽  
Chao Ming Hsu ◽  
Shang Ping Wei
Keyword(s):  
Effective Strain ◽  
Fem Simulation ◽  
Assembly Model ◽  
Multi Stage ◽  
Solid Models ◽  
Assembly Drawing ◽  
Three Stages ◽  
Forging Force ◽  
Realistic Experiment ◽  
Good Agreement

This study uses the dies of the dray fasteners processing graphics provided by the fastener’s industry to establish 3D dies and components solid models based on the embedded drawing function tools provided by the component model (Standard.ipt) of Autodesk Inventor CAD software. After finishing the dies and components drawing, the integrated assembly drawing of dies can be obtained through the assembly model (Standard.iam) firstly. Three stages forming processes can be conducted and carried out the FEM simulation to check the forming acceptance. The effective stress, the effective strain, the velocity field, and the forging force can be obtained by the FEM simulation. Moreover, the realistic experiment can be performed to verify the acceptance of FEM simulation. The dimensions of final product can be measured to get the errors between FEM and experiment. It is noted that the errors show a good agreement with the experiment.

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.

Redrawing Operation a Star Shape from Cylindrical Shape Using Experimental and FE Analysis

2020 ◽  
Vol 38 (1A) ◽  
pp. 25-32
Author(s):  
Waleed Kh. Jawad ◽  
Ali T. Ikal
Keyword(s):  
Finite Element ◽  
Effective Strain ◽  
Element Model ◽  
Cylindrical Shape ◽  
Element Analysis ◽  
Punch Force ◽  
Maximum Value ◽  
Element Simulation ◽  
Blank Sheet ◽  
The Finite Element Model

The aim of this paper is to design and fabricate a star die and a cylindrical die to produce a star shape by redrawing the cylindrical shape and comparing it to the conventional method of producing a star cup drawn from the circular blank sheet using experimental (EXP) and finite element simulation (FES). The redrawing and drawing process was done to produce a star cup with the dimension of (41.5 × 34.69mm), and (30 mm). The finite element model is performed via mechanical APDL ANSYS18.0 to modulate the redrawing and drawing operation. The results of finite element analysis were compared with the experimental results and it is found that the maximum punch force (39.12KN) recorded with the production of a star shape drawn from the circular blank sheet when comparing the punch force (32.33 KN) recorded when redrawing the cylindrical shape into a star shape. This is due to the exposure of the cup produced drawn from the blank to the highest tensile stress. The highest value of the effective stress (709MPa) and effective strain (0.751) recorded with the star shape drawn from a circular blank sheet. The maximum value of lamination (8.707%) is recorded at the cup curling (the concave area) with the first method compared to the maximum value of lamination (5.822%) recorded at the cup curling (the concave area) with the second method because of this exposure to the highest concentration of stresses. The best distribution of thickness, strains, and stresses when producing a star shape by

scholarly journals Multi-Stage Cold Forging Process for Manufacturing a High-Strength One-Body Input Shaft

Materials ◽  
2021 ◽  
Vol 14 (3) ◽  
pp. 532
Author(s):  
A Jo ◽  
Myeong Jeong ◽  
Sang Lee ◽  
Young Moon ◽  
Sun Hwang
Keyword(s):  
High Strength ◽  
Microstructural Characterization ◽  
Fatigue Tests ◽  
Machining Process ◽  
Cold Forging ◽  
Element Analysis ◽  
Forging Process ◽  
Input Shaft ◽  
Multi Stage ◽  
The One

A multi-stage cold forging process was developed and complemented with finite element analysis (FEA) to manufacture a high-strength one-body input shaft with a long length body and no separate parts. FEA showed that the one-body input shaft was manufactured without any defects or fractures. Experiments, such as tensile, hardness, torsion, and fatigue tests, and microstructural characterization, were performed to compare the properties of the input shaft produced by the proposed method with those produced using the machining process. The ultimate tensile strength showed a 50% increase and the torque showed a 100 Nm increase, confirming that the input shaft manufactured using the proposed process is superior to that processed using the machining process. Thus, this study provides a proof-of-concept for the design and development of a multi-stage cold forging process to manufacture a one-body input shaft with improved mechanical properties and material recovery rate.

Sign in / Sign up

Export Citation Format

Share Document