Cold forged parts are mainly employed in automotive and aerospace assemblies, and strength plays an essential role in such applications. Backward extrusion is one such process in cold forging for the production of axisymmetrical cup-like parts, which is affected by a number of variables that influence the quality of the products. The study on the influencing parameters becomes necessary as the complexity of the part increases. The present paper focuses on the use of a multi-layered feed forward artificial neural network (ANN) model for determining the effects of process parameters such as billet size, reduction ratio, punch angle, and land height on forming behavior, namely, effective stress, strain, strain rate, and punch force in a cold forging backward extrusion process for AISI 1010 steel. Full factorial design (FFD) has been employed to plan the finite element (FE) simulations and accordingly, the input variables and response patterns are obtained for training from these FE simulations. This ANN model-based analysis reveals that the forming behavior of the cold forging backward extrusion process tends to increase with the billet size as well as the reduction ratios. However, decreases in punch angle and land height lead to the reduction of punch forces, which in turn enhances the punch life. FE simulation along with the developed ANN model scheme would benefit the cold forging industry in minimizing the process development effort in terms of cost and time.
Experiential/activity based learning is the process of learning through doing an activity and is thought to be useful to increase the retention of theoretical concepts and will help in bridging the gap between theory and practice. The inspiration for this work is the fact that learning can be fruitful only when the class-room theoretical concepts are visualized/ experienced through laboratory practice and is the essence of experiential/activity based learning teaching practices. The attempt has been made to bridge the gap between theory and real-time industry practices by means of open ended activity learning for the undergraduate course of V-semester Manufacturing Technology-Metal Forming. In today's era numerical simulation as a component of the virtual manufacturing concept of sheet metal forming has emerged as one of the important processes in manufacturing technology. This has resulted in reduced lead time and increased product quality. To inculcate these concepts to the students for a better understanding, a metal forming simulation software has been incorporated as part of this activity. Here student groups identified the sheet metal components (which included the sheet metal forming operations like shearing, bending, deep-drawing, etc.). They carried the design, modeling, simulation, analysis and interpreted the results. This activity not only helped students to get acquainted with the design process, but also lead to better understanding of class-room theoretical concepts. A close resemblance is experienced by students between the simulation results and theoretical calculation which resulted in cognitive and synergic atmosphere for learning among the students and by this the outcome b-"Ability to design and perform laboratory experiments for manufacturing & allied systems as well as to analyze and interpret data" of ABET 3b has been achieved.
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