The Rationalization of Production of Ring-Shaped Drop Forgings Using Computer Simulation of Closed-Die Forging Process

2015 ◽  
Vol 660 ◽  
pp. 335-339
Author(s):  
Mária Kapustová
Keyword(s):  
Energy Savings ◽  
Simulation Software ◽  
Advanced Technology ◽  
Material Loss ◽  
Bulk Forming ◽  
Die Forging ◽  
Closed Die Forging ◽  
Alloy Type ◽  
Drop Forging ◽  
Important Position

The rationalization of ring-shaped drop forgings production may be considered from different points of view. Important aspects of evaluation and selection of optimal production alternative are material and energy savings and issue of forging tool life. This contribution describes advanced technology of closed die forging without flash, which represents an effective method of manufacture of ring-shaped drop forging from steel alloy type 16MnCr5. This proposed method offers a cheaper possibility of production of mentioned forging piece resulting from saving of batch material. At present drop forgings with this shape are produced by an uneffective method, i.e. die forging with flash, which brings a considerable material loss. Simulation software determined for simulation of bulk forming processes have an important position at development of new advanced technologies of drop forgings production. A simulation program MSC.SuperForge described in this contribution was used in order to verify correct plastic flow of material in closed die cavity.

Numerical Simulation Analysis on Cold Closed-Die Forging of Differential Satellite Gear in Car

2008 ◽  
Vol 575-578 ◽  
pp. 517-524 ◽  
Author(s):  
Yao Zong Zhang ◽  
Jian Bo Huang ◽  
Xue Lin ◽  
Quan Shui Fang
Keyword(s):  
Numerical Simulation ◽  
Simulation Analysis ◽  
Simulation Software ◽  
Bevel Gear ◽  
Cold Forging ◽  
Forging Process ◽  
Die Forging ◽  
Closed Die Forging ◽  
Forming Defects ◽  
Deform 3D

The cold closed-die forging process of the gear is a kind of new technique of the precise forming of gear in recent years. In this paper, the cold closed-die forging process of differential satellite gear in car was analyzed through numerical simulation method. Forming mold was designed with Pro/E Wildfire2.0 which included four components : upper punch, lower punch, tooth shape upper die and lower die for Normal Cone. The three-dimensional models of satellite bevel gear mould were built and imported into numerical simulation software DEFORM-3D. Because the gear has the uniform circumferential features, in order to save time and improve the accuracy, only one tooth was simulated, and the full simulation outcome of 10 teeth was mirrored from this one. Through the numerical simulation analysis of DEFORM-3D, the instantaneous deformation and stress filed were gained. Forming defects were forecasted and the cold closed-die forging rule for satellite gear used in car was obtained which can provide effective references for no-flash cold forging process of planet bevel gear and the mold design.

The Description of Precision Forging Technology in Closed Die of Mg Alloy AZ31 Using Computer Simulation

2014 ◽  
Vol 686 ◽  
pp. 78-81 ◽  
Author(s):  
Mária Kapustová ◽  
Jozef Bílik
Keyword(s):  
Automotive Industry ◽  
Primary Objective ◽  
Pollutant Emissions ◽  
Dominant Position ◽  
Bulk Forming ◽  
Precision Forging ◽  
Die Forging ◽  
Numeric Simulation ◽  
Alloy Type ◽  
Further Development

Automotive industry is nowadays constantly strengthening its dominant position. Its primary objective is to reduce weight of automobiles in order to decrease fuel consumption and amount of harmful pollutant emissions. From the viewpoint of further development in the field of automotive industry, very interesting are the issues of die forgings production from light non-ferrous metals. This article describes research of precision die forging technology in closed die with regard to magnesium alloy type AZ 31. Given alloy type Mg-Al-Zn is suitable for bulk forming and is characterized by good formability at hot conditions. Results of this research may be applied to production of forgings with longitudinal shape, e.g. levers and connecting rods. In order to verify the design of forging technology in closed die for lever-shaped forged piece the simulation program MSC.SuperForge was used. Numeric simulation of die forging process confirmed suitable designed shape and dimensions of semi product and also correct material plastic flow in cavity of closed die.

Preform design in axial hot closed die forging by isothermal surface method. Part 1. Overview of preform design methods. Theoretical aspects and algorithm of preform shape design

2021 ◽  
pp. 214-220
Author(s):  
A.V. Vlasov ◽  
D.V. Krivenko ◽  
S.A. Stebunov ◽  
N.V. Biba ◽  
A.M. Dyuzhev
Keyword(s):  
Simulation Software ◽  
Preform Design ◽  
Mathematical Basis ◽  
Design Algorithm ◽  
Forming Simulation ◽  
Die Geometry ◽  
Die Forging ◽  
Closed Die Forging ◽  
Trial And Error Method ◽  
Preform Shape

Methods of preform design in hot-die forging are analyzed. It is noted that despite numerous works in this fi eld, preform design is still often based on the trial-and-error method. The isothermal surfaces method for preform design is proposed and its mathematical basis is considered. The procedure for determining of the preform shape is given. The design algorithm uses the QForm metal forming simulation software to build isothermal surfaces and check in the quality of the designed die geometry by finite element modeling, as well as specially developed version of the QFormDirect CAD based on SpaceClaim™.

The Precision Forging Experiment of Mg Alloy Drop Forging Using Computer Simulation

2014 ◽  
Vol 1064 ◽  
pp. 175-180
Author(s):  
Mária Kapustová ◽  
Jozef Bílik
Keyword(s):  
Rapid Development ◽  
Production Costs ◽  
Precision Forging ◽  
Ferrous Metals ◽  
Die Forging ◽  
Numeric Simulation ◽  
Closed Die Forging ◽  
Alloy Type ◽  
Non Ferrous Metals ◽  
Increasing Demand

Rapid development of automotive industry brings increasing demand for die forgings made from non-ferrous metals. Market economy stimulates drop forges to produce forged pieces of highest quality and dimension precision with the accent on reduction in production costs. Precision die forging without flash belongs to progressive and economical technologies of die forgings production. This paper describes an experiment of precision forging in closed die of magnesium alloy type AZ 31. Given alloy type Mg-Al-Zn is suitable for bulk forming and is characterized by good hot formability. Achieved results may be applied in practice at production of longitudinal shaped forgings e.g. levers and connecting rods. In order to verify a design of closed die forging technology regarding the lever-shaped forged piece, simulation program MSC.SuperForge was used. Numeric simulation was significantly helpful at optimization of semi-product shape and dimensions and confirmed correct plastic flow of material in closed die cavity. The objective of this contribution was to point out current trends in searching for economical measures at production of die forgings from alloys of non-ferrous metals.

Slip Line Field Analysis of a Simple Plane Strain Closed-Die Forging

1989 ◽  
Vol 203 (2) ◽  
pp. 91-99
Author(s):  
M V Srinivas ◽  
P Alva ◽  
S K Biswas
Keyword(s):  
Velocity Field ◽  
Plane Strain ◽  
Slip Line ◽  
Field Analysis ◽  
Line Field ◽  
Slip Line Field ◽  
Die Forging ◽  
Closed Die Forging ◽  
Cavity Filling ◽  
Single Cavity

A slip line field is proposed for symmetrical single-cavity closed-die forging by rough dies. A compatible velocity field is shown to exist. Experiments were conducted using lead workpiece and rough dies. Experimentally observed flow and load were used to validate the proposed slip line field. The slip line field was used to simulate the process in the computer with the objective of studying the influence of flash geometry on cavity filling.

Three-Dimensional Analysis of Closed-Die Forging Processes: Part 1: Formulation

1989 ◽  
Vol 203 (1) ◽  
pp. 33-37 ◽  
Author(s):  
C F Lugora ◽  
A N Bramley
Keyword(s):  
Theoretical Model ◽  
Energy Dissipation ◽  
Metal Flow ◽  
Three Dimensional ◽  
Total Rate ◽  
Die Forging ◽  
Closed Die Forging ◽  
Proposed Model ◽  
Optimum Velocity ◽  
Forging Load

In this series of papers, a theoretical model based on the upper bound elemental technique is presented for prediction of forging load and metal flow in three-dimensional closed-die forging processes. Three basic elements are introduced in order to partition a forging into simple elementary regions. An optimum velocity distribution within the forging is obtained by minimizing the total rate of energy dissipation using a simplex optimizing procedure. Applications of the proposed model are discussed in Part 2.

Mechanics of Closed-Die Forging (Phase II)

1972 ◽  
Author(s):  
James R. Douglas ◽  
Taylan Altan
Keyword(s):  
Phase Ii ◽  
Die Forging ◽  
Closed Die Forging

A Research on the Cold Closed-Die Forging of Bevel Gears

2021 ◽  
pp. 27-32
Author(s):  
Pham Quang Trung ◽  
Nguyen Hoang Dung ◽  
Nguyen Nhat Minh
Keyword(s):  
Bevel Gears ◽  
Die Forging ◽  
Closed Die Forging
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