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.

Study on Cylindrical Heatsink Forging Process Considering Friction Condition

2019 ◽  
Vol 823 ◽  
pp. 141-144
Author(s):  
Tung Sheng Yang ◽  
Yong Nan Chen
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Friction Factor ◽  
Testing Machine ◽  
Metal Flow ◽  
Compression Tests ◽  
Stress Strain ◽  
Element Analysis ◽  
Forging Process ◽  
Different Temperatures

The feasibility of forging of AL-1050 alloy of cylindrical heatsink under warm conditions is demonstrated in the present work. The stress-strain curves and friction factor play an important role in the cylindrical heatsink forging. The purpose of forging lubrication is to reduce friction between blank and die, and to decrease resistance of metal flow to die. The stress-strain curves at different temperatures are obtained by compressing tests. The friction factor between 1050 aluminum alloy and die material are determined at different temperatures by ring compression tests with graphite lubricants. The compressing and ring compressing tests are carried out by using the computerized screw universal testing machine. The finite element method is used to investigate the forming characters of the forging process. To verify the prediction of FEM simulation in the cylindrical heatsink forging process, the experimental parameters such as stress-strain curves and fiction factor, are as the input data during analysis. Maximum forging load and effective stress distribution are determined of the heatsink forging, using the finite element analysis. Finally, the cylindrical heatsink parts are formed by the forging machine under the conditions using finite element analysis.

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.

A Three-Dimensional Finite Element Analysis of the Cold Forging of a Model Aluminium Connecting Rod

1985 ◽  
Vol 199 (4) ◽  
pp. 319-324 ◽  
Author(s):  
I Pillinger ◽  
P Hartley ◽  
C E N Sturgess ◽  
G W Rowe
Keyword(s):  
Computer Simulation ◽  
Finite Element ◽  
Strain Hardening ◽  
Metal Flow ◽  
Three Dimensional ◽  
Cold Forging ◽  
Connecting Rod ◽  
Element Analysis ◽  
Hardening Material ◽  
Elastic Plastic

A fully three-dimensional elastic-plastic finite element method is used to simulate metal flow during the most complex stage of the cold forging of a model of an aluminium connecting rod. The results of the computer simulation are compared with the forging of strain-hardening aluminium billets using graphite lubrication. The analysis predicts deformation patterns and hardness distributions which have been checked by selected experiments. The experimental results show inhomogeneous deformation in various parts of the forging and noticeable variations in the formation of flash around its periphery, features which are also found in the analyses. The elastic-plastic finite element technique can thus satisfactorily be applied to three-dimensional forgings of strain-hardening material. The work described here represents one part of a continuing research programme to develop computer simulation techniques for the modelling of complex cold, warm or hot industrial forgings.

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.

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.

Analysis on Temperature Field of Work-Piece during Cross Wedge Rolling

2011 ◽  
Vol 230-232 ◽  
pp. 352-356
Author(s):  
Wen Ke Liu ◽  
Kang Sheng Zhang ◽  
Zheng Huan Hu
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Flow ◽  
Work Piece ◽  
Contact Deformation ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Rigid Plastic ◽  
Finite Element Software ◽  
Deform 3D

Based on the rigid-plastic deformation finite element method and the heat transfer theories, the forming process of cross wedge rolling was simulated with the finite element software DEFORM-3D. The temperature field of the rolled piece during the forming process was analyzed. The results show that the temperature gradient in the outer of the work-piece is sometimes very large and temperature near the contact deformation zone is the lowest while temperature near the center of the rolled-piece keeps relatively stable and even rises slightly. Research results provide a basis for further study on metal flow and accurate shaping of work-piece during cross wedge rolling.

Forging Process Analysis of 6061 Aluminum Alloy Motorcycle Brake Parts

2021 ◽  
Vol 901 ◽  
pp. 176-181
Author(s):  
Tung Sheng Yang ◽  
Chieh Chang ◽  
Ting Fu Zhang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Metal Forming ◽  
Process Analysis ◽  
Surface Hardness ◽  
Dimensional Accuracy ◽  
Die Design ◽  
Element Analysis ◽  
Forging Process

This paper used finite element analysis of metal forming to study the forging process and die design of aluminum alloy brake parts. According to the process parameters and die design, the brake parts were forged by experiment. First, the die design is based on the product size and considering parting line, draft angle, forging tolerance, shrinkage and scrap. Secondly, the finite element analysis of metal forming is used to simulate the forging process of aluminum alloy brake parts. Finally, the aluminum alloy brake levers with dimensional accuracy and surface hardness were forged.

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