Development of A Plate-type Cold Forging Manufacturing Process and Finite Element Analysis for Producing Thrust Washer of Automotive Engine

2018 ◽  
Vol 27 (1) ◽  
pp. 46-56 ◽  
Author(s):  
Bongki Kang ◽  
Joonghyun Yoon ◽  
Joono Cheong ◽  
Hyunhwan Jeong ◽  
Wonseok Lee ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Manufacturing Process ◽  
Cold Forging ◽  
Element Analysis ◽  
Automotive Engine ◽  
Plate Type

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

2014 ◽  
Vol 970 ◽  
pp. 177-184 ◽  
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.

Finite element analysis for temperature distributions in a cold forging

2013 ◽  
Vol 27 (10) ◽  
pp. 2979-2984
Author(s):  
Dongbum Kim ◽  
Sungwook Kim ◽  
Inchul Song ◽  
Byungcheol Jeon ◽  
Inhwan Lee ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Cold Forging ◽  
Element Analysis ◽  
Temperature Distributions

PREDICTION OF THE RESIDUAL STRESS IN THE PROCESS OF STRAIGHTENING WIRE

2008 ◽  
Vol 22 (31n32) ◽  
pp. 6039-6044 ◽  
Author(s):  
TAE WON KIM ◽  
MYOUNG GYU LEE ◽  
HYUNG-IL MOON ◽  
HYUNG JONG KIM ◽  
HEON YOUNG KIM
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Manufacturing Process ◽  
Added Value ◽  
Element Analysis ◽  
Active Research

Microwire made using a straightening process has high added value and has been adopted in many fields of industry. There is much active research on the straightening process. Very straight microwire can be obtained by removing the residual stress induced during the manufacturing process. Generally, the residual stress is removed or minimized through several drawing steps with heat treatment. This study used finite element analysis to calculate the residual stress during each straightening process and investigated the main reason for a change in stress.

Finite element analysis for precision cold forging of helical gear using recurrent boundary conditions

1998 ◽  
Vol 212 (3) ◽  
pp. 231-240 ◽  
Author(s):  
Y B Park ◽  
D Y Yang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Boundary Conditions ◽  
Three Dimensional ◽  
Helical Gear ◽  
Cold Forging ◽  
Rigid Plastic ◽  
Element Analysis ◽  
The Finite Element Analysis ◽  
Good Agreement

In metal forming, there are problems with recurrent geometric characteristics without explicitly prescribed boundary conditions. In such problems, so-called recurrent boundary conditions must be introduced. In this paper, as a practical application of the proposed method, the precision cold forging of a helical gear (which is industrially useful and geometrically complicated) has been simulated by a three-dimensional rigid-plastic finite element method and compared with the experiment. The application of recurrent boundary conditions to helical gear forging analysis is proved to be effective and valid. The three-dimensional deformed pattern by the finite element analysis is shown, and the forging load is compared with the experimental load. The profiles of the free surface of the workpiece show good agreement between the computation and the experiment.

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