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

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.

The Technological Optimization of Closed Multiple-Ram Forging for Draw Rod

2010 ◽  
Vol 29-32 ◽  
pp. 2339-2344
Author(s):  
Chun Dong Zhu ◽  
Tai Liang Dai ◽  
Hui Wang
Keyword(s):  
Numerical Simulation ◽  
Steering System ◽  
Original Material ◽  
Forming Process ◽  
High Quality ◽  
Mechanical Parts ◽  
Optimal Technology ◽  
Simulation Results ◽  
Material Utilization ◽  
Open Die Forging

Draw rod is one of the main mechanical parts of vehicle steering system，which is required extremely high quality. At present the way to produce the draw rod is machining after common open-die forging. This technology will produce big flashings，damage the metal’s fibrous structure and reduce the material utilization. In this essay, we will use the technology of closed multiple-ram forging to produce it. We will utilize numerical simulation on several blanks through numerical simulation combined with experiments. In this way, the defects that some parts of the blank are folded and cannot fill well during forming process can be effectively avoided. Besides, there will be free of flashing and the draw rod forgings do not need to be cut. The weight of the original blank will be about 3.5 kg after being optimized, down by 36.4 percent compared with that of original material about 5.5 kg. And we will make different settings for the loading way of the plunger chips during the forming process, then compare with the simulation results and ultimately find out the best loading way. At last, we will verify the feasibility of such an optimal technology through experiments on the material-lead.

scholarly journals The Effect of Swinging Ball Heads with Different Arrangements in Multi-Point Stretch-Forming Process

Materials ◽  
2019 ◽  
Vol 12 (3) ◽  
pp. 337 ◽  
Author(s):  
Jian Xing ◽  
Yan-yan Cheng ◽  
Zhuo Yi
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Sheet Metal ◽  
Strain Distribution ◽  
Finite Element Models ◽  
Stretch Forming ◽  
Forming Process ◽  
Forming Quality ◽  
Staggered Arrangement ◽  
Simulation Results

To improve the effect of multi-point stretch forming of sheet metal, it is proposed in this paper to replace a fixed ball head with a swinging ball head. According to the multi-point dies with different arrangements, this research establishes finite element models of the following stretch forming, i.e., fixed ball heads with conventional arrangement, swinging ball heads with conventional arrangement, swinging ball heads with declining staggered arrangement, and swinging ball heads with parallel staggered arrangement, and then numerical simulation is performed. The simulation results show that by replacing a fixed ball head with a swinging ball head, the surface indentation of the part formed was effectively suppressed, the stress and tension strain distribution of the part formed was improved, and the forming quality was improved; the thickness of the elastic pad was reduced, the springback was reduced and the forming accuracy was improved; and when the ball head was applied to a multi-point die with staggered arrangement, a better forming result was achieved, where the best forming result was achieved in combining the swinging ball heads with the multi-point die with a parallel staggered arrangement. Forming experiments were carried out, and the experimental results were consistent with the trend of numerical simulation results, which verified the correctness of the numerical simulation.

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.

Study on the Forming Process of the Crossmember in Car Intermediate Floor

2013 ◽  
Vol 442 ◽  
pp. 593-598
Author(s):  
Xue Xia Wang ◽  
Peng Chong Guan ◽  
Hai Peng Li ◽  
Li Hui Wang ◽  
Na Zhang ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Numerical Model ◽  
Process Parameters ◽  
Thickness Distribution ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Simulation Technology ◽  
Forming Process ◽  
Distribution Diagram ◽  
Simulation Results

Flanging and bending forming processes of the crossmember in car intermediate floor are investigated respectively by using numerical simulation technology. The numerical model of the crossmember was established and its press forming effect was simulated to determine the feasible process parameters affecting its manufacturability. Forming limit diagram and thickness distribution diagram are used to evaluate simulation results of different process schemes. And then optimum values of process parameters for flanging and bending are found, which can reduce the tendencies of wrinkling, springback and crackling during the stamping of the product.

Physical modeling and numerical simulation of V-die forging ingot with central void

2014 ◽  
Vol 228 (13) ◽  
pp. 2347-2356 ◽  
Author(s):  
Peter Christiansen ◽  
Jesper H Hattel ◽  
Niels Bay ◽  
Paulo AF Martins
Keyword(s):  
Numerical Simulation ◽  
Physical Modeling ◽  
Small Scale ◽  
Pure Lead ◽  
Die Forging ◽  
Multi Stage ◽  
Deformation Mechanics ◽  
Open Die Forging ◽  
Central Void ◽  
Forging Load

Numerical simulation and physical modeling performed on small-scale ingots made from pure lead, having a hole drilled through their centerline to mimic porosity, are utilized to characterize the deformation mechanics of a single open die forging compression stage and to identify the influence of the lower V-die angle on porosity closure and forging load requirements of large cast ingots. Results show that a lower V-die angle of 120° provides the best closure of centerline porosity without demanding the highest forging loads or developing unreasonably asymmetric shapes that may create difficulties in multi-stage open die forging procedures.

Forming Stability Analysis of Surface Flexible Rolling

2013 ◽  
Vol 798-799 ◽  
pp. 267-271
Author(s):  
Ren Jun Li ◽  
Ming Zhe Li ◽  
Zhong Yi Cai
Keyword(s):  
Numerical Simulation ◽  
Stability Analysis ◽  
Sheet Metal ◽  
Three Dimensional ◽  
Continuous Manufacturing ◽  
Forming Process ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Flexible Rolling ◽  
Simulation Results

Surface flexible rolling method, using two integral working rolls as the forming tool, can achieve fast, flexible and continuous manufacturing of three-dimensional sheet metal parts. This paper introduces the basic principle of surface flexible rolling and discusses the numerical simulation results when the working rolls are bended as circular arcs. The stability indicates the forming effect to some extent and the flow type of the metal can be deduced from stability analysis. To integrate and analyze the simulation results by means of reverse engineering. The analysis results show that the forming process is stable and the effect of surface flexible rolling is fine. It also indicates that inhomogeneous deformation and accumulation occurs during the process. The numerical simulation and experimental results demonstrate that the surface flexible rolling is a feasible and effective way to form three-dimensional sheet metal parts.

Relations between numerical simulation and experiment in closed die forging of a gear

2006 ◽  
Vol 177 (1-3) ◽  
pp. 256-260 ◽  
Author(s):  
M. Skunca ◽  
P. Skakun ◽  
Z. Keran ◽  
L. Sidjanin ◽  
M.D. Math
Keyword(s):  
Numerical Simulation ◽  
Die Forging ◽  
Closed Die Forging ◽  
Simulation And Experiment

scholarly journals Closed-die Forging Technology and Numerical Simulation of Aluminum Alloy Connecting Rod

Open Physics ◽  
2019 ◽  
Vol 17 (1) ◽  
pp. 497-504
Author(s):  
Wei Zhang ◽  
Yandong Yu
Keyword(s):  
Aluminum Alloy ◽  
Flow Characteristics ◽  
Deformation Mode ◽  
Connecting Rod ◽  
Forming Process ◽  
Forming Load ◽  
Die Forging ◽  
Closed Die Forging ◽  
Study Results ◽  
Deformation Velocity

Abstract In order to improve quality and reveal the law of precision forging, closed-die forging technology is used in this paper to conduct a numerical analysis of the forming process of aluminum alloy connecting rod by the DEFORM software. Forming effects under different loading modes were acquired, and forming process, blank flow characteristics, stress-strain distribution and load-stroke curve characteristics were analyzed. Study results indicate that the forming effect under the loading mode featuring first movement of lateral punch and then movement of upper and lower punches is good with high quality forge piece and no defect, the closed-die forging technology of aluminum alloy connecting rod is reasonable and feasible. Under a certain deformation velocity and deformation mode, aluminum alloy connecting rod forming load firstly reduces and then increases, the forming load is in direct proportion to deformation velocity. When the forming process is finished, forming load reaches 130T, it accords with the production practice. The study results provide a certain reference for guiding the formulation of closed-die forging production technology of aluminum alloy connecting rods.

Sign in / Sign up

Export Citation Format

Share Document