Hollow Lateral Extrusion of Tubular Billets – Further Development of the Cold Forging Process

2015 ◽  
Vol 794 ◽  
pp. 160-165 ◽  
Author(s):  
Jonas Wälder ◽  
Mathias Liewald
Keyword(s):  
Structural Design ◽  
Metal Forming ◽  
Room Temperature ◽  
Cold Forging ◽  
Forming Process ◽  
Forging Process ◽  
Lateral Extrusion ◽  
Funded Project ◽  
Hollow Billets ◽  
Further Development

Light weight engineering in structural design and use of lighter materials are becoming increasingly important in bulk metal forming. Results gained by a DGF funded project which will be introduced in the following, concerning novel advancements of hollow lateral extrusion. Paper exhibits further development of this process, so cold forged components having undercuts without using a lateral tool plane easily can be manufactured. Thereby, the focus of attention is on the tool design as well as on the analysis of the unmodified forming process. Therefore, experimentally investigations have been carried out, failures on components are analyzed and process limitations of an experimental setup for cold forging of hollow billets at room temperature are illustrated.

Improvement of Hole Flanging Product Forming Process Using Finite Element Simulation

2010 ◽  
Vol 97-101 ◽  
pp. 344-347 ◽  
Author(s):  
Xue Wen Chen ◽  
Jun Wei Zhao ◽  
Dong Won Jung
Keyword(s):  
Metal Forming ◽  
Cold Forging ◽  
Forming Process ◽  
Forging Process ◽  
Counter Pressure ◽  
Element Simulation ◽  
Metal Forming Process ◽  
Die Set ◽  
Hole Flanging ◽  
Deform 3D

Flanging is a method of sheet metal forming process under combined compressive and tensile conditions using a punch and die to raise closed rims (flanges or collars) on pierced holes. For the flanging product used for the automotive steering part, the thickness of the bottom radius area is very important because of the crack usually occurred during the using process. But during conventional flanging process, the thickness of the rim and the bottom radius area were decreased seriously and make the hole flanging not strong enough to be used. In order to increase the thickness of bottom radius area of the flanging wall, a new method that combines flanging process and cold forging process was proposed in this paper and a special forming die set was designed with a stripper subjected to counter-pressure with an aim to obtain a more substantial flange. FEM software DEFORM 3D was employed to simulate these flanging part forming processes. The results showed the thickness of bottom radius area of the flanging wall was increased and a more substantial flange was obtained.

Querfließpressen und Verschieben*/Lateral extrusion and shifting

2017 ◽  
Vol 107 (10) ◽  
pp. 708-713
Author(s):  
M. Prof. Liewald ◽  
L. Pasler
Keyword(s):  
Numerical Simulation ◽  
New Technology ◽  
Cold Forging ◽  
Forming Process ◽  
Tensile Stresses ◽  
Lateral Extrusion

Mit dem neu entwickelten Verfahren, das Querfließpressen mit gleichzeitigem Verschieben kombiniert, lassen sich exzentrische Wellen oder kurbelwellenartige Bauteile durch Kaltfließpressen herstellen. Der Vorteil im Unterschied zur Verfahrenskombination von Stauchen und anschließendem Verschieben ist, dass das Querfließpressen ein Nachführen von Material während des Umformprozesses in die Umformzone ermöglicht. Aufgrund der verfahrensbedingten geringeren Zugspannungen in der Kurbelwange sind mit dem neuen Verfahren erweiterte Verfahrensgrenzen beim Versatz zu erwarten. Dieser Fachbeitrag beschreibt das Verfahrensprinzip, das Werkzeugkonzept und die numerische Auslegung des Prozesses.   The new technology of combined lateral extrusion and simultaneous shifting allows producing eccentric shafts or crankshaft-like components by cold forging. The advantage of lateral extrusion compared to an upsetting and subsequent shifting is the constant web thickness. For this, material is pushed into the forming zone during the forming process. It is expected that this will result in lower tensile stresses and thus lower damage in the crankshaft web. This paper describes the process, tooling concept and numerical simulation of the combined lateral extrusion and shifting process.

Study on the Large Module Spur Gear Cold Forming Process by Means of Numerical Simulation

2011 ◽  
Vol 189-193 ◽  
pp. 2642-2646 ◽  
Author(s):  
Qian Li ◽  
Yi Bian ◽  
Zhi Ping Zhong ◽  
Gui Hua Liu ◽  
Ying Chen
Keyword(s):  
Numerical Simulation ◽  
Simulation Method ◽  
Spur Gear ◽  
Cold Forging ◽  
Forming Process ◽  
Cold Forming ◽  
Forging Process ◽  
Flow Method ◽  
Precision Forging ◽  
Cold Precision Forging

The cold forging process of large module spur gear with four modules and 59mm breadth is performed by means of numerical simulation method. Two processes to forming such spur gears were compared by the simulation method, one is with the closed-die performing and extrusion in the finish-forging, the other is with divided-flow method in the finish-forging. Especially, the divided-flow method is analyzed in detail. The necessary reference and basis to realize practical cold precision forging process of spur gear with large modulus is provided eventually.

scholarly journals LOAD PREDICTION ON METAL FORMING PROCESS (FORGING) USING FINITE ELEMENT METHOD.

2020 ◽  
Vol 2 (1) ◽  
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Metal Forming ◽  
Weighted Residual Method ◽  
Forming Process ◽  
Residual Method ◽  
Forging Process ◽  
Metal Forming Process ◽  
Metal Blank ◽  
Element Method

Metal forming process is a widely used manufacturing process especially in high volume metal production system. In this paper, the main objective is using Bubnov-Galerkin finite element model to derive the pressure field set up at various cross-sections of a metal blank during a forging process, and the four Lagrange quadratic elements were assembled to represent the various metal blank. The governing equation adopted for this paper is a one-dimensional differential equation describing the pressures exerted on the forging process. During the analysis, the various metal blanks are divided into a finite number of elements and the weighted integral form for each element were formed after applying the Bubnov-Galerkin weighted residual method. A matrix form under certain boundary conditions from the weighted residual method were used to obtain the pressure distribution across the cross-section of the various metal blanks. Finite element results are obtained for a value of a circular disc diameter, thickness, coefficient of friction, principal stress, length, and radius of a circular material. Finite element method and the Exact solution approach are used to achieve and compare both results. Furthermore, the combination of both methods shows that there are potentials for using this approach towards the optimization of metal forming in manufacturing processes and some engineering practices. Keywords: Forging; LaGrange Interpolation Function; Bubnov-Galerkin Weighted Residual Method; Finite Element Method.

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.

Application of Blank Optimization Method in Deep Drawing of Rectangular Magnesium Alloy Cups under Non-Isothermal Condition

2007 ◽  
Vol 344 ◽  
pp. 333-339
Author(s):  
W.T. Zheng ◽  
Donato Sorgente ◽  
G. Palumbo ◽  
Luigi Tricarico ◽  
Li Mei Ren ◽  
...  
Keyword(s):  
Magnesium Alloy ◽  
Deep Drawing ◽  
Metal Forming ◽  
Room Temperature ◽  
Isothermal Condition ◽  
Optimization Methods ◽  
Optimization Method ◽  
Forming Process ◽  
Metal Forming Process ◽  
Blank Shape

Using the optimum blank in sheet metal forming process not only can decrease the material wasting but also avoid possible defects such as local severe thinning, wrinkling and fracture. Since it is practical technology for industrial production, many blank optimization methods have been proposed and their validity was verified by some forming tests of typical or complicated components. However, all the forming tests were carried out at room temperature or under isothermal condition. In present work, a blank optimization method was employed to evaluate its efficiency in deep drawing of rectangular magnesium alloy cups under non-isothermal condition. It is proved by experiment that the employed blank optimization method can predict successfully the optimum initial blank shape for the component with specified shape and dimension.

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.

Evaluation of Different Influencing Factors in Dry Sheet Metal Forming with Vaporizing CO2 Used as Lubricant

2015 ◽  
Vol 794 ◽  
pp. 53-58 ◽  
Author(s):  
Markus Singer ◽  
Mathias Liewald
Keyword(s):  
Sheet Metal ◽  
Process Parameters ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Mineral Oil ◽  
Work Piece ◽  
Forming Process ◽  
Ecological Requirements ◽  
Further Development

Lubricants in sheet metal forming have to meet increasing demands resulting from political aims and ecological requirements. For that reason, industry aspires the reduction of lubrication with the long term goal of replacing conventional mineral oil based lubricants entirely. Dry metal forming to a certain limit can be achieved by using liquid CO2 during the forming process. This lubricant vaporizes after deep drawing process and leaves a clean work piece that can be used in coating or joining processes without any subsequent cleaning. In this contribution, further development and resulting effects of numerous process parameters are evaluated and presented. Investigations of restraining forces in strip draw tests when lubricated with liquid CO2 include different tool parameters like drilling diameters (120 and 140 µm), different numbers of drillings (25 and 49) as well as different process parameters like surface pressure (2,5 and 6,5 MPa) or drawing speed (50 and 100 mm/s). Amount of restraining forces in this paper also are compared to two different conventional mineral oil based lubricants (Wisura AK 3080 and Wisura ZO 3368). The results presented in this contribution may provide a better understanding of tribological mechanisms emerging within this new lubrication system.

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.

Numerical Simulation of Forging Process of Spiral Bevel Gear

2012 ◽  
Author(s):  
Rong-Jer Lai
Keyword(s):  
Bevel Gear ◽  
Raw Material ◽  
Cold Forging ◽  
Spiral Bevel Gear ◽  
Forming Process ◽  
Forging Process ◽  
Design Concepts ◽  
The Coefficient Of Friction ◽  
Suitable Combination ◽  
Spiral Bevel

In this paper different cold forging processes of spiral bevel gear are studied based on the patent analysis. First of all, various design concepts are analyzed and classified according to the type of raw material and the motion of die during the forming process. Then, focused on the bulk billet, the parameters such as the mode of die motion, the size and shape of initial billet, the speed of punch and the coefficient of friction are selected to study their effects on the cold forging process. Finally, following the Taguchi method, numerical simulations are carried out to find out the suitable combination of process parameters. Material flow, stress and strain distributions as well as forging load are analyzed.

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