Numerical Simulation and Analysis of Forging Process for Automotive Starter Motor Ring Gear
DEFORM-3D software is a powerful simulation tool that uses the Finite Element Method to analyze the three dimensional complex forging process, It provides a virtual testing environment in which engineers can study the influence of geometric parameters, process parameters and other factors on forging process performance. This paper aims at the forging process of automotive starter motor ring gear, and suitable technology parameters have been determined, which is combined with the numerical simulation by FEM method. The variation of metal flow, stress and strain were obtained. And an experiment was employed to prove that he simulation result and the experimental result tallies well. This research plays a guiding role on the optimal design of the forging processes and dies structure for similar parts.
Process analysis of multistage forging by using finite element method
Abstract Much progress in forging technology including low production cost and fast production has allowed an intensive use of forging. Manufacturing companies have especially focused on producing a complex shaped part with a tight dimensional tolerance. Traditional warm and cold forging methods have their own limitations to produce such a complex shaped part; warm forging requires complex system with relatively higher manufacturing cost, while cold forging is not applicable to materials with limited formability. Therefore, multistage forging may be advantageous to produce complex shaped parts. In order to build a multistage forging system, it is necessary to characterize mechanical properties in response to system design parameters such as temperature, forging speed and reduction. For the analysis of formability of multistage forging process, finite element method (FEM) has been used for the process analysis. As a model case, a constant velocity (CV) joint forging process is analyzed by FEM, since CV joint has a complex shape and also its required dimensional tolerances are very tight. A systematic approach to process analysis is established using the FEM for the multistage forging of the CV joint outer race.
Increasing tool life in cold forging through advanced design and tool manufacturing techniques
Abstract In this paper, results of two investigations concerned with the evaluation and prediction of fatigue failure and the improvement of tool service life in cold forging are presented. The first study presents an integrated approach to tool stress analysis and shows its possible application for a punch failure case provided by industry. The second study experimentally investigates measures that can be taken during design and tooling manufacture to reduce fatigue failure. Both studies clearly indicate the value of performing a tool stress analysis during the process and tool design phase.