scholarly journals Automotive CVT sheave development using complex forging processes

2018 ◽  
Vol 7 (3.3) ◽  
pp. 329
Author(s):  
Wen Kun Peng ◽  
Sung Young Park
Keyword(s):  
Metal Flow ◽  
Hot Forging ◽  
Tensile Tests ◽  
Machining Process ◽  
Product Development Process ◽  
Cold Forging ◽  
Forging Process ◽  
Flow Test ◽  
Core Part ◽  
Material Cutting

Background/Objectives: In this study, we developed a complex forging process to produce a sheave, which is a core part of CVT for automobiles, fabricated prototypes. The existing processes such as hot forging and the MCT machining process have disadvantages including excessive amounts of material cutting, number of processes, and processing time.Methods/Statistical analysis: To overcome these shortcomings, in this study, a shape was created using hot forging and the shape was molded into a precision part using cold forging. A complex forging process was developed that enabled maximization of the metallographic density and reduction of material cutting quantity by applying a minimal number of processes. By conducting heat compression and tensile tests of the samples, we identified the physical properties of the material and used the commercial software Deform-3D to conduct a forging analysis.Findings: Based on the analysis results, we designed a combined process of hot forging and cold forging and fabricated a mold and pilot products. The fabricated pilot products were evaluated using a metal flow test, an internal defect test, a surface roughness test, etc. According to the evaluation results, no significant defect was observed, and we therefore believe it is adequate for mass production.Improvements/Applications: The complex forging method can reduce the use of material by approximately 15% compared with the hot forging and the MCT machining process. Through this study, we established a product development process using a high-precision complex forging technology.  

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.

One Action Press Forming of Helix Bevel Gear by Using Multi-Cylinder Press and Die Heating System

2018 ◽  
Vol 12 (5) ◽  
pp. 767-774
Author(s):  
Katsuaki Nakamura ◽  
◽  
Hiroshi Koresawa ◽  
Hiroyuki Narahara
Keyword(s):  
Hot Forging ◽  
High Hardness ◽  
Heating System ◽  
Bevel Gear ◽  
Cold Forging ◽  
Machining Time ◽  
Forging Process ◽  
Forged Parts ◽  
Almost All ◽  
Forging Press

In the case of a complex shaped helix bevel gear, the forging of complete gear tips is very difficult to achieve. In almost all cases, tooth profile is finished by cutting machine from simple shaped forged parts, therefore requiring considerable machining time and cost. However, there are many approaches to forging. Forging is mainly classified as hot and cold forging, and uses a single motion press. In the case of hot forging takeoff of products from die is difficult by the cooling shrinkage from die and accuracy of products is lower level than cold forging. In addition, in the case of cold forging, a complicated shape is difficult to achieve based on the lack of ductility of the materials. To realize a helix bevel gear using a single forging operation, we applied a tool heating system and three-axis forging press. The tool heating system is applied to prevent a temperature decrease in the material by contact between the tool and forging material during the forging process. Further, to optimize the forging direction and timing, we used a three-axis forging press. We confirmed good forging capability of this special forging process, as well as the high precision of the forged parts. Moreover, through the thermo-mechanical control of steel and the tool temperature, the forged parts showed good mechanical properties, such as high hardness.

scholarly journals Development of Preform for Simulation of Cold Forging Process of A V8 Engine Camshaft Free from Flash & Under-Filling

Mathematics ◽  
2019 ◽  
Vol 7 (11) ◽  
pp. 1026
Author(s):  
A.N. Saquib ◽  
H.M.T. Khaleed ◽  
Irfan Anjum Badruddin ◽  
Ali Algahtani ◽  
M.F. Addas ◽  
...  
Keyword(s):  
Finite Element ◽  
Process Development ◽  
Wide Spectrum ◽  
Metal Flow ◽  
Volumetric Analysis ◽  
Cold Forging ◽  
Work Piece ◽  
Element Analysis ◽  
Forging Process ◽  
Two Factors

Finite Element Method based techniques apply to a wide spectrum of engineering applications including manufacturing. The flexibility to achieve optimized results by simulations adds another dimension to process-development. The efficiency due to simulation is enhanced many folds for developing desired components by reducing the cost as well as time. This paper investigates cold forging process to be adopted to produce camshafts with a target to minimize flash as well as under filling. These two factors being major problems encountered when cold forging is to be adopted for complex shaped products. The current work is primarily concerned with the development of an optimized preform design for a V8 engine camshaft. The work involved the Solid modeling of the camshaft on AutoCAD and further analyzing the developed model through finite element analysis using Deform 3D. The analysis involved understanding of metal flow, volumetric analysis and die stresses in the forging process. The materials considered for the work-piece and the dies are AISI 8620 and AISI-H-26 respectively. The sample camshaft was taken from a standard Dodge Challenger V8 engine. 10 different cases are analyzed to find out the best possible scenario. It is fund that the stress level for the developed model was very much within the design limit of the material.

Hot Deformation Behavior of Bearing Steels

2007 ◽  
Vol 129 (3) ◽  
pp. 349-355 ◽  
Author(s):  
Ho Keun Moon ◽  
Jae Seong Lee ◽  
Sun Joon Yoo ◽  
Man Soo Joun ◽  
June Key Lee
Keyword(s):  
Testing Machine ◽  
Metal Flow ◽  
Hot Forging ◽  
Tensile Tests ◽  
Internal Crack ◽  
Compression Tests ◽  
Bearing Steels ◽  
Material Behaviors ◽  
Bearing Race ◽  
Hot Forging Process

The material behaviors of two types of bearing steels at hot working conditions are investigated. Stress-strain curves at various temperatures (900–1300°C) and strain rates (1–50/s) are obtained by compression tests with a computer controlled servo-hydraulic Gleeble 3800 testing machine. Elongation and reduction of the area are also obtained by tensile tests with the Gleeble 1500 testing machine. Flow stresses are calculated from the experiments and are used to predict the temperature distribution and the metal flow of a workpiece during a multistage hot forging process of a bearing race. A rigid-thermoviscoplastic finite element method is applied. The experimental and numerical results are summarized to reveal the reasons for internal crack formation.

Flash Design for Automatic Transfer System of Bearing Hub in Hot Forging Process

2006 ◽  
Vol 116-117 ◽  
pp. 120-123
Author(s):  
Sang Kon Lee ◽  
Hyun Sang Byun ◽  
Byung Min Kim ◽  
Dae Cheol Ko ◽  
C.G. Kang
Keyword(s):  
Numerical Analysis ◽  
Metal Flow ◽  
Hot Forging ◽  
Experimental Results ◽  
Transfer System ◽  
Forging Process ◽  
Hot Forging Die ◽  
Forging Die ◽  
Hot Forging Process ◽  
Forging Load

The aim of this study is to design flash geometry of bearing hub to apply the automatic transfer system in hot forging process. The flash geometry is very important in hot forging process because the flash geometry effects on the metal flow, material losses, forging load, die pressure and so on. In this study, the problem of designing the flash geometry is studied with flash thickness and width considering the maximum die pressure to apply an automatic transfer system in hot forging process for bearing hub. The numerical analysis was conducted by means of the commercial S/W DEFORM. On the basis of numerical analysis the flash geometry of hot forging die was redesigned, and experiment was conducted. From the experimental results, it was possible to produce bearing hub with an automatic transfer system without any deterioration of die lifetime.

Investigation on metal flow and forming load of bi-metal gear hot forging process

2016 ◽  
Vol 88 (9-12) ◽  
pp. 2835-2847 ◽  
Author(s):  
Pengfei Wu ◽  
Baoyu Wang ◽  
J. Lin ◽  
Bin Zuo ◽  
Zhi Li ◽  
...  
Keyword(s):  
Metal Flow ◽  
Hot Forging ◽  
Forging Process ◽  
Forming Load ◽  
Hot Forging Process

scholarly journals A comparative analysis of hot and cold flashless forging of a stepped shaft using vertically-parted dies

2021 ◽  
Author(s):  
Tomasz Bulzak ◽  
Janusz Tomczak ◽  
Zbigniew Pater
Keyword(s):  
Comparative Analysis ◽  
Metal Forming ◽  
Effective Strain ◽  
Hot Forging ◽  
Cold Forging ◽  
Geometrical Parameters ◽  
Forging Process ◽  
Stepped Shaft ◽  
One Step ◽  
Hot Forging Process

AbstractFlashless forging is classified as a precise metal forming technology. The main advantages of this technology are the reduction of the flash allowance and the shortening of the manufacturing time by eliminating the flash trimming operation. The article presents the process of one-step forging of a stepped shaft made of aluminum with the use of split dies. The process was carried out in cold and hot metal-forming conditions. The forging process was analyzed numerically using the Simufact Forming 15.0 software. The geometrical parameters of the obtained product were analyzed, and the distribution of effective strain, temperature, and the standardized cracking criterion was determined. The process force parameters were also determined. Numerical tests were verified in real conditions with the use of a specially designed device for forging in vertical split dies. Comparison of hot and cold forging in vertical split dies is presented. The comparative analysis results have demonstrated that the hot forging process has more advantages than the cold forging process. The hot forging process ensures higher accuracy of forged parts.

Quality Cost Analysis of Typical Forging Based on SPC and DEA Model

2015 ◽  
Vol 1095 ◽  
pp. 808-815
Author(s):  
Shu Hai Huang ◽  
Xiang Sheng Xia
Keyword(s):  
Hot Forging ◽  
Cold Forging ◽  
Statistical Process ◽  
Quality Cost ◽  
Production Program ◽  
Forging Process ◽  
Quality Costs ◽  
New Process ◽  
Failure Cost ◽  
Warm Forging

In order to control the quality costs of forgings efficiently and ensure the optimization of enterprise production value input and benefit output, using piston, output shaft and other typical forgings as application objects, choosing cold and warm forging process instead of the former single hot forging or cold forging process, reinforcing Statistical Process Control (SPC) of processing quality and appropriately distributing quality failure cost and quality assurance cost in order to efficiently match the total cost of quality, quality process capacity index and production program so that the stability of forging quality can be improved. Using Data Envelopment Analysis (DEA) to contrast and analysis the quality cost data of new process and old process, of which the result shows that the technical input and benefit output of new process accord with mass production requirements in the prior period of enterprise industrialization.

Cold Forging Process Analysis and Precision Progressive Die for Cam of Low-Carbon Steel

2010 ◽  
Vol 44-47 ◽  
pp. 2733-2736
Author(s):  
Dao Chun Hu ◽  
Lei Wang
Keyword(s):  
Process Analysis ◽  
Metal Flow ◽  
Low Carbon Steel ◽  
Cold Forging ◽  
Low Carbon ◽  
Forming Process ◽  
Element Analysis ◽  
Progressive Die ◽  
Pilot Hole ◽  
Forging Process

This paper analyzes the forming process methods of cam in CPU socket to control its open and close. The whole process is pierce, notch, the first forging forming, the second pierce(the second pilot hole), the second forging forming(sizing), impact forging forming, and trimming. The punch shape design of the first forging forming is simulated by finite element analysis. The optimized punch profile radius 0.50mm and punch size Φ10.60mm are available. Cold forging of precision progressive die is put forward. The second pierce pilot hole that newly designed is applied, which relief the deformation of pilot holes caused by severe metal flow. Compared with the traditional single operation dies, the precision progressive die based on cold forging process were proved through the practical production to be high economical efficiency, which could be the references for developing the cold forging process of producing the similar produsts.

Sign in / Sign up

Export Citation Format

Share Document