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.

Fully Coupled Finite Element Analysis of an Automatic Multi-Stage Cold Forging Process

2020 ◽  
Vol 311 ◽  
pp. 88-93
Author(s):  
Jong Bok Byun ◽  
Hyun Joon Lee ◽  
Jong Bok Park ◽  
Il Dong Seo ◽  
Man Soo Joun
Keyword(s):  
High Strength ◽  
Material Model ◽  
Die Design ◽  
Cold Forging ◽  
Complete Analysis ◽  
Analysis Model ◽  
Element Analysis ◽  
Forging Process ◽  
Multi Stage ◽  
Analysis Scheme

In this paper, non-isothermal analysis of an automatic multi-stage cold forging process of a ball-stud is conducted using a new material model which is a closed form function of strain, temperature and strain rate covering low and warm temperatures for high-strength stainless steel SUS304. An assembled die structural analysis scheme is employed for revealing the detailed die stresses, which is of great importance for process and die design for metal forming of the materials with high strengths. Die elastic deformation is dealt with to predict final geometries of material with higher accuracy. A complete analysis model is proposed to be used for optimal design of process and die designs in automatic multi-stage cold forging of high-strength materials.

scholarly journals Experimental and numerical investigation of the overload effect on fatigue behaviour of spot-welded steel sheets

2018 ◽  
Vol 106 (3) ◽  
pp. 309 ◽  
Author(s):  
Fabienne Pennec ◽  
Bianzeubé Tikri ◽  
Sébastien Bergamo ◽  
Michel Duchet ◽  
Bastien Weber ◽  
...  
Keyword(s):  
Failure Modes ◽  
Hsla Steel ◽  
High Strength ◽  
Fatigue Behaviour ◽  
Fatigue Tests ◽  
Favourable Effect ◽  
Low Alloy Steels ◽  
Element Analysis ◽  
Alloy Steels ◽  
Spot Welded

Spot-weld joints are commonly used to fasten together metal sheets in automotive industry. The car frame used in Renault vehicles is a representative example of the usefulness of this method. Most of the spot-welds experience fatigue damaging occurrence due to rough roads or driving conditions which apply periodical overloads to the vehicle. Understanding their fatigue behaviour is crucial from the viewpoint of failure prevention in design. In this study, a series of experiments was conducted to study the fatigue failure of spot-welded tensile-shear specimens made of a deep-drawing steel (XES) and High strength low alloy steels (HE360D and XE360D). Two different types of fatigue tests were performed, the first one with a constant-amplitude sinusoidal loading (loading ratio equal to 0.1) and the second one with one incidental overload cycle introduced per 100 cycles. The experimental results show a favourable effect of overloads for HSLA steel specimens, whereas the effect is the opposite for XES steel specimens. A finite element analysis was carried out using the open-source Salome-Meca platform to determine the stress states within the specimens around the weld spot and explains both failure modes observed on the specimens at high and low loads.

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.

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.

Analysis of Cold Preforming Process for Hollow Fasteners with Thin Flange

2013 ◽  
Vol 418 ◽  
pp. 246-249
Author(s):  
Ting Ping Chang ◽  
Shyh Chour Huang ◽  
Te Fu Huang ◽  
Thanh Phong Dao
Keyword(s):  
Finite Element Analysis ◽  
Deformation Behavior ◽  
Cold Forging ◽  
Forming Process ◽  
Element Analysis ◽  
Forging Process ◽  
Plastic Deformation Behavior ◽  
The Finite Element Analysis ◽  
Simulation Results ◽  
Future Work

This paper aims to study and detect the imperfects of the hollow fasteners with thin flange during cold forging process. In this study, the finite element analysis (FEA) based on 3-D DEFORMTM software to investigate the plastic deformation behavior of the hollow fasteners with thin flange. The simulation results showed that there is a folding phenomenon, which is occurring in the forming process. As a result, it revealed that with using FEA, the imperfects of forming hollow fasteners with the thin flange can be correctly predicted. From that, the occurrence of defects can be effectively prevented in the actual fabricating process. Future work will include an investigation into the optimization of the mold geometric parameters during cold pre-forming process for hollow fasteners with thin flange by comparing the simulative and experimental results.

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.  

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