Research on Closed Die Forging Process of Car Steering Knuckle

2008 ◽  
Vol 575-578 ◽  
pp. 204-209 ◽  
Author(s):  
De Ying Zhao ◽  
Lian Dong Zhang ◽  
Hui Xue Sun
Keyword(s):  
Numerical Simulation ◽  
High Energy ◽  
Extrusion Pressure ◽  
Forming Process ◽  
Forging Process ◽  
Dimensional Precision ◽  
Die Forging ◽  
Closed Die Forging ◽  
Plastic Forming ◽  
Die Extrusion

Steering knuckle, which has strict requirements with regard to dimensional precision and quality, is a key component in cars. Conventional plastic forming methods are involved with intricate procedures and high energy consumptions. Normally, a 40 MN hot die forging press or a 100 KJ electro-hydraulic hammer is required to produce the steering knuckle. Closed die forging, which is a new precision forming technology developed in recent years, has some virtues, such as good mechanical properties, easy to form and improving of metal plastic deformation. Aiming at Jetta steering knuckle in this paper, the technology of two forging steps in one heat is presented. This technology is mainly composed of precision pre-forging, which is a closed die extrusion with the extrusion belt, and open finish-forging. The pre-forging process and finish-forging process are numerically simulated using the FEM software DEFORM-3D. For the closed die extrusion forming process, which is the key component of the technology, some key problems were researched, such as the flowing and filling regularity, extrusion-belt length, punch size, punch movement, lubrication and the relationship between the clamping pressure and the extrusion pressure. For the finish-forging process, the flowing and filling regularity of the finish-forging part was studied to verify the correct shape and dimension of the pre-forging part. Numerical simulation with regard to the pre-forging process shows that the closed die forging can not only help to form the pre-forging part, but also decrease the extrusion pressure to be less than 8 MN, extend the mould’s service life and increase the utilization ratio of materials to be more than 75%. Numerical simulation of the finish-forging process shows that the pre-forging part design is rational. In addition, the forging experiments were carried out using the dies designed in particular. The experiments show that the technology is feasible and can markedly improve the mechanical property of the forging piece.

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.

Numerical Simulation and Experimental Verification of Disc Cutter Rings in Die Forging Process

2021 ◽  
Vol 13 (1) ◽  
pp. 131-139
Author(s):  
Luhan Hao ◽  
Tao Wang ◽  
Kangping Fu ◽  
Zhengyang Zhao ◽  
Yun Chen ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Metal Flow ◽  
Element Model ◽  
Disc Cutter ◽  
Forging Process ◽  
Die Forging ◽  
Plastic Forming ◽  
Simulation Results ◽  
The Finite Element Model ◽  
Good Agreement

In order to study the forming law of the disc cutter ring in the independently researched die, the finite element model (FEM) of disc cutter ring for die forging has been established and the die forging process has been simulated by the plastic forming software. The metal flow field, temperature field, stress and strain field of the filling process were obtained by simulation. The exerted force of the die was also simulated and analyzed; thus, the die forging process was optimized. Based on the designed process parameters and simulation results, the experimental study on die forging forming of cutter ring was carried out. The comparison shows that the numerical simulation results are in good agreement with the experimental results, which proves that the die forging model of disc cutter ring in this paper is feasible.

Study on the Cold Closed-Die Forging of Planetary Bevel Gears

2013 ◽  
Vol 803 ◽  
pp. 321-325
Author(s):  
Feng Kang ◽  
E Chuan Yang ◽  
Yan Bin Wang ◽  
Qiang Chen ◽  
Da Yu Shu
Keyword(s):  
Numerical Simulation ◽  
High Precision ◽  
Cold Forging ◽  
Dimensional Precision ◽  
Bevel Gears ◽  
Die Forging ◽  
Closed Die Forging ◽  
Die Stress

Taking the Planetary Bevel Gears as an object, the characteristic of cold Closed-die Forging was studied. By Using the FEM, the flowing rule of metal in the process of cold forging were analyzed, which is composed of dual-direction extrusion, upsetting and filling the gear form. The results show that each district of cavity was filled completely at the end of forging, without corner collapse, fold or crack. Taken the lower die as an example, the distribution of die stress was also analyzed. The results of numerical simulation were proved by the experiments, meanwhile the high precision and quality forging was formed. To the gears, the cold closed-die forging can not only ensure the dimensional precision, but also improve the capability of the gear, while obviously reduce materials consumption.

The Numerical Simulation of Conductive Body Forming Process and Mould Design

2011 ◽  
Vol 704-705 ◽  
pp. 177-182
Author(s):  
Jian Xin Gao ◽  
Pei Feng Zhao ◽  
Ke Xing Song ◽  
Qing Wang
Keyword(s):  
Numerical Simulation ◽  
Machining Process ◽  
Forming Process ◽  
Die Forging ◽  
Conductive Body ◽  
Closed Die Forging ◽  
Draft Angle ◽  
Simulation Results ◽  
Open Die Forging ◽  
Ring Blank

T2-copper conductive body is a important part used in high voltage switch, it has poor machining process due to the complex shape. Through Deform numerical simulation, conductive body was formed by open-die forging and closed die forging. In the open-die forging simulation，heat transfer coefficient between blank (880°C) and open-die (200°C) is 11, the surrounding environment temperature is 20°C, friction factor is 0.3. The main open-die forging process parameters is: outer draft angle α=6.5°; inner draft angle β＝10°; bridge width b＝5、8、11mm. punching skin and cylindrical blank. Simulation results show that forging can meet the requirement while properly adjusting mould parameters. The main size of closed-die forging working parts is designed according to the conductive body graph, no draft angle and ring blank of external diameter Φ111mm and inside diameter Φ93mm with the same volume of conductive body. The simulation results shows that forging can be formed using open-die forging, and it is difficult to form product by the process of the closed-die forging for ring blank because of the restriction of solid state metal liquidity, many regions of the filling is not sufficient. Open-die forging and casting blank-closed die forging are both used in actual production. The casting blank-closed die forging is a more reasonable forming process compared with the open-die forging as metal volume of distribution is solved, higher utilization rate of material, more simple process in following work and the like. To make it more suitable for practical production, appropriate adjustments of some parameters was made in the mold design process based on the numerical simulation. Keywords: open-die forging; casting blank–closed die forging; numerical simulation

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.

Development of a CAD/CAM system for the closed-die forging process

2003 ◽  
Vol 138 (1-3) ◽  
pp. 436-442 ◽  
Author(s):  
M Jolgaf ◽  
A.M.S Hamouda ◽  
S Sulaiman ◽  
M.M Hamdan
Keyword(s):  
Forging Process ◽  
Die Forging ◽  
Closed Die Forging ◽  
Cad Cam

Numerical Simulation of Non-Circular Hole Joint Precision Forming

2009 ◽  
Vol 16-19 ◽  
pp. 462-465
Author(s):  
Yong Fei Gu ◽  
Jun Ting Luo
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Finite Element ◽  
Circular Hole ◽  
Developed Countries ◽  
Forming Process ◽  
Backward Extrusion ◽  
Forming Technology ◽  
Plastic Forming ◽  
And Performance

The precision forming technology developed rapidly during passing two decades, however technologies of precision plastic forming the parts with deeper hole are far behind developed countries. The warm backward extrusion-ironing forming technology was presented for precision forming of non-circular hole joint in this paper. The forming process and parameter variable trend were simulated by finite element method, which the software MSC.Marc was applied. The forming die was designed and the forming experiment was finished. The products were deserved with good quality and performance. The feasibility of the forming technology is proved by experimental results and numerical simulation.

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