Finite Element Analysis of Precision Cold Forging Process to Improve Material Utilization for Injector Housing

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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Rigid-Plastic Finite Element Simulation of Cold Forging and Sheet Metal Forming by Eulerian Meshing Method

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.970.177 ◽

2014 ◽

Vol 970 ◽

pp. 177-184 ◽

Cited By ~ 1

Author(s):

Wen Chiet Cheong ◽

Heng Keong Kam ◽

Chan Chin Wang ◽

Ying Pio Lim

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Large Deformation ◽

Sheet Metal ◽

Metal Forming ◽

The Body ◽

Cold Forging ◽

Rigid Plastic ◽

Element Analysis ◽

Linear Solution

A computational technique of rigid-plastic finite element method by using the Eulerian meshing method was developed to deal with large deformation problem in metal forming by replacing the conventional way of applying complicated remeshing schemes when using the Lagrange’s elements. During metal forming process, a workpiece normally undergoes large deformation and causes severe distortion of elements in finite element analysis. The distorted element may lead to instability in numerical calculation and divergence of non-linear solution in finite element analysis. With Eulerian elements, the initial elements are generated to fix into a specified analytical region with particles implanted as markers to form the body of a workpiece. The particles are allowed to flow between the elements after each deformation step to show the deforming pattern of material. Four types of cold forging and sheet metal clinching were conducted to investigate the effectiveness of the presented method. The proposed method is found to be effective by comparing the results on dimension of the final product, material flow behaviour and punch load versus stroke obtained from simulation and experiment.

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Finite Element Analysis of the Forging Process for Half-Shaft Bushing

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.16-19.1248 ◽

2009 ◽

Vol 16-19 ◽

pp. 1248-1252

Author(s):

Chun Dong Zhu ◽

Man Chun Zhang ◽

Lin Hua

Keyword(s):

Finite Element Method ◽

Finite Element Analysis ◽

Finite Element ◽

Numerical Calculation ◽

Two Dimensional ◽

Element Analysis ◽

Forging Process ◽

Die Life ◽

Dimensional Finite Element ◽

Forging Force

As an important forged part of an automobile, the inner hole of the half-shaft bushing must be formed directly. However, the process requires many steps, and how the forging, or deformation, is spread over the production steps directly affects the die life and forging force required. In this paper, the three steps involved in directly forging a half shaft bushing's inner hole are simulated using the two-dimensional finite element method. Further more, we improve the forging process. From numerical calculation, the improved necessary forging force is found to be only half the original force, and the die life is doubled.

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Study on Cylindrical Heatsink Forging Process Considering Friction Condition

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.823.141 ◽

2019 ◽

Vol 823 ◽

pp. 141-144

Author(s):

Tung Sheng Yang ◽

Yong Nan Chen

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Friction Factor ◽

Testing Machine ◽

Metal Flow ◽

Compression Tests ◽

Stress Strain ◽

Element Analysis ◽

Forging Process ◽

Different Temperatures

The feasibility of forging of AL-1050 alloy of cylindrical heatsink under warm conditions is demonstrated in the present work. The stress-strain curves and friction factor play an important role in the cylindrical heatsink forging. The purpose of forging lubrication is to reduce friction between blank and die, and to decrease resistance of metal flow to die. The stress-strain curves at different temperatures are obtained by compressing tests. The friction factor between 1050 aluminum alloy and die material are determined at different temperatures by ring compression tests with graphite lubricants. The compressing and ring compressing tests are carried out by using the computerized screw universal testing machine. The finite element method is used to investigate the forming characters of the forging process. To verify the prediction of FEM simulation in the cylindrical heatsink forging process, the experimental parameters such as stress-strain curves and fiction factor, are as the input data during analysis. Maximum forging load and effective stress distribution are determined of the heatsink forging, using the finite element analysis. Finally, the cylindrical heatsink parts are formed by the forging machine under the conditions using finite element analysis.

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