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.

Semi-Enclosed Cold Forging Process Analysis and Progressive Die Design of CPU Fin

2008 ◽  
Vol 575-578 ◽  
pp. 174-179
Author(s):  
Juan Hua Su ◽  
Feng Zhang Ren ◽  
Lei Wang
Keyword(s):  
Production Efficiency ◽  
High Efficiency ◽  
Process Analysis ◽  
Die Design ◽  
Cold Forging ◽  
Forming Process ◽  
Element Analysis ◽  
Whole Process ◽  
Progressive Dies ◽  
Transfer Unit

This paper analyzes the forming process methods of fin used in CPU chip to emit heat. The whole process is blanking, the first forging forming, the second forging (sizing), and trimming. The chamfer design of CPU fin blank is simulated by finite element analysis. The optimized chamfer 1.6 mm is available. Semi-enclosed cold forging of progressive dies is put forward. The newly designed transfer unit is applied, which unifies the merit of high efficiency of the progressive dies and the high material-using ratio of the project die. Quick disassembly structure is designed and pins are used as quick disassembly pins by means of ball bearing bushing. The unique processing of the shearing scrap structure is adopted when designing the inverted trimming dies. Compared with the traditional die, the mechanization and electrization are realized to increase the production efficiency and get highly precise CPU fin.

Measurement and Calculation of Elastic Properties in Low Carbon Steel Sheet

2005 ◽  
Vol 495-497 ◽  
pp. 1591-1596 ◽  
Author(s):  
Vladimir Luzin ◽  
S. Banovic ◽  
Thomas Gnäupel-Herold ◽  
Henry Prask ◽  
R.E. Ricker
Keyword(s):  
Carbon Steel ◽  
Elastic Property ◽  
Elastic Properties ◽  
Steel Sheet ◽  
Low Carbon Steel ◽  
Low Carbon ◽  
Forming Process ◽  
Element Analysis ◽  
Wide Range ◽  
Carbon Steel Sheet

Low carbon steel (usually in sheet form) has found a wide range of applications in industry due to its high formability. The inner and outer panels of a car body are good examples of such an implementation. While low carbon steel has been used in this application for many decades, a reliable predictive capability of the forming process and “springback” has still not been achieved. NIST has been involved in addressing this and other formability problems for several years. In this paper, texture produced by the in-plane straining and its relationship to springback is reported. Low carbon steel sheet was examined in the as-received condition and after balanced biaxial straining to 25%. This was performed using the Marciniak in-plane stretching test. Both experimental measurements and numerical calculations have been utilized to evaluate anisotropy and evolution of the elastic properties during forming. We employ several techniques for elastic property measurements (dynamic mechanical analysis, static four point bending, mechanical resonance frequency measurements), and several calculation schemes (orientation distribution function averaging, finite element analysis) which are based on texture measurements (neutron diffraction, electron back scattering diffraction). The following objectives are pursued: a) To test a range of different experimental techniques for elastic property measurements in sheet metals; b) To validate numerical calculation methods of the elastic properties by experiments; c) To evaluate elastic property changes (and texture development) during biaxial straining. On the basis of the investigation, recommendations are made for the evaluation of elastic properties in textured sheet metal.

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.

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.

Powdering in Coating Layer of Galvannealed Nb-Ti Free Extra Low Carbon Steel Sheet

2007 ◽  
Vol 345-346 ◽  
pp. 1089-1092
Author(s):  
S.I. Kim ◽  
D.J. Paik ◽  
Shi Hoon Choi ◽  
D.W. Kim ◽  
Y.C. Yang ◽  
...  
Keyword(s):  
Fracture Behavior ◽  
Volume Fraction ◽  
Coating Layer ◽  
Low Carbon Steel ◽  
Bending Test ◽  
Low Carbon ◽  
Forming Process ◽  
Element Analysis ◽  
Steel Sheets ◽  
Hardness Variation

We have studied the fracture behavior of coating layer when low and high alloying galvannealed (GA) steels are subject to forming process. To understand better powdering features in the coating layer of the steel sheets, we carried out V-bending test and a series of finite element analysis which simulates damage characteristics in the coating layer. Results showed that the powdering behavior in the coating is significantly affected by the soundness and volume fraction of phases in the coating layer. The hardness variation of coating layers attributed to different phases leads to different deformation behavior of the coating layer itself.

Servo Forging Technology and Mold Development of the Pulley of AISI-1010 Low Carbon Steel

2018 ◽  
Vol 917 ◽  
pp. 257-261
Author(s):  
Tung Sheng Yang ◽  
Chun Wang ◽  
Li Xiu Liu ◽  
Shuen Huei Yao
Keyword(s):  
Carbon Steel ◽  
Pulse Wave ◽  
Equivalent Stress ◽  
Low Carbon Steel ◽  
Simulation Software ◽  
Cold Forging ◽  
Low Carbon ◽  
Forming Force ◽  
Forging Process ◽  
Maximum Equivalent Stress

Aimed at AISI-1010 low carbon steel pulley components, a finite element method-based metal forming simulation software of DEFORM 3D was used to simulate and analyze the near net forging process for the low carbon steel pulley, and to design forging molds. This technology was used in the pulley tooth forging in conjunction with the servo press-based servo motion curve technology. First, the cold forging process of the pulley preform forging and the near net forging were simulated. Also, the applications of the pulse wave servo motion curve in the pulley tooth forging was simulated, which was compared with the traditional motion curve-based forging forming, where the comparisons focused on the maximum forming force and maximum equivalent stress. The results indicated that the maximum forming force and the maximum equivalent stress of the punch caused by the pulse wave servo motion curve was smaller than caused by the traditional motion curve.

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.

Microstructure Integrated Modeling of Multiscan Laser Forming

2002 ◽  
Vol 124 (2) ◽  
pp. 379-388 ◽  
Author(s):  
Jin Cheng ◽  
Y. Lawrence Yao
Keyword(s):  
Flow Stress ◽  
Numerical Models ◽  
Flow Behavior ◽  
Fem Simulation ◽  
Constitutive Models ◽  
Low Carbon Steel ◽  
Laser Forming ◽  
Low Carbon ◽  
Forming Process ◽  
Heating And Cooling

Laser forming of steel is a hot forming process with high heating and cooling rate, during which strain hardening, dynamic recrystallization, and phase transformation take place. Numerical models considering strain rate and temperature effects only usually give unsatisfactory results when applied to multiscan laser forming operations. This is mainly due to the inadequate constitutive models employed to describe the hot flow behavior. In this work, this limitation is overcome by considering the effects of microstructure change on the flow stress in laser forming processes of low carbon steel. The incorporation of such flow stress models with thermal mechanical FEM simulation increases numerical model accuracy in predicting geometry change and mechanical properties.

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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