The article refers to an analysis of the multi-operation process of manufacturing a hub type forging used to transmit power in motorcar gear boxes, by way of die forging on a crank press. The investigations were performed in order to improve the currently realized production technology, mainly with the use of numerical simulations. Through the determination of the key parameters/quantities during forging, which are difficult to determine directly during the industrial process, an in-depth and complex analysis was performed by way of FE (Finite Element) modelling. A thermomechanical model of producing a hub forging with deformable tools was developed with the use of the Qform 9.0.9 software. For the elaboration and construction of the forging tool CAD (Computer Aided Design) models, the Catia V5R20 program was applied. The results of the performed numerical modelling made it possible to determine the material flow and the properness of the filling of impressions, as well as the temperature field distributions and plastic deformations in the forging; it was also possible to detect the forging defects often observed in the industrial process. On this basis, the changes in the process were determined, which enabled an improvement of the presently realized technology and the obtaining of proper forgings, both in respect of quality and dimensions and shape.
The study presents the concept of physical modelling together with the characterization of the modelling materials as well as the possibilities of applying this type of physical simulation methods for the analysis, design and optimization of industrial metal forming processes. The paper discusses the crucial similarity conditions between the physical model and the real process necessary to transform the results into industrial processes. Physical modelling is one of the most popular as well as cheapest methods of analyzing metal plastic forming processes and it can constitute an easy independent verifying tool. It can also be a competitive alternative or supplementation, or a quick verification, of the popular yet relatively expensive methods based on a broadly understood mathematical apparatus, e.g. the finite element method or various types of computer science techniques. The method provides the possibility to define the stress and deformation distribution, estimate the force parameters of the given process as well as localize the dead zones and material flow errors. On the example of a forward extrusion process, the study demonstrates the effect of matching the model material to two metallic materials: annealed aluminum and reinforced aluminum. Additionally, for reinforced aluminum, numerical modelling was performed, which made it possible to determine e.g.: the force parameters and the material flow manner. Next, based on physical modelling, verification through numerical modelling was made of the boundary and tribological conditions, as physical modelling revealed a so-called dead zone in the corner of the die, which had not been recorded in numerical modelling.
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