Application of the finite element method in cold forging processes

Abstract

The demand for more efficient manufacturing processes has been increasing in the last few years. The cold forging process is presented as a possible solution, because it allows the production of parts with a good surface finish and with good mechanical properties. Nevertheless, the cold forming sequence design is very empirical and it is based on the designer experience. The computational modeling of each forming process stage by the finite element method can make the sequence design faster and more efficient, decreasing the use of conventional "trial and error" methods. In this study, the application of a commercial general finite element software - ANSYS - has been applied to model a forming operation. Models have been developed to simulate the ring compression test and to simulate a basic forming operation (upsetting) that is applied in most of the cold forging parts sequences. The simulated upsetting operation is one stage of the automotive starter parts manufacturing process. Experiments have been done to obtain the stress-strain material curve, the material flow during the simulated stage, and the required forming force. These experiments provided results used as numerical model input data and as validation of model results. The comparison between experiments and numerical results confirms the developed methodology potential on die filling prediction

Implementation of finite element analysis for solving the constraints in forming process of large steel parts

“…These requirements of the above challenges need to concentrate the concerns on the development of the metal forming sector through adopting an accurate procedure [5]. In work [6], the finite element method as computational modeling is used in each forming stage of analysis of the progressive deformation to make the design efficient, and faster, and decrease the trial and error time. However, there are many upsetting problems related to the high surface area need to be solved.…”

Optimizing Hot Forging Process Parameters of Hollow Parts Using Tubular and Cylindrical Workpiece: Numerical Analysis and Experimental Validation

“…Due to the geometry of the part, a 3D simulation was used, the results of which are more reliable and fit better to the hot forging process. These considerations are indicated in the literature by the software manufacturer and others studies [8].…”

“…Through numerical simulation, it is possible to find process routs for reducing the manufacturing time and consequently, the cost [7]. In recent years, the mechanical forming industry has been experiencing a major advance in the design area due to the improvement of the numerical simulation programs of this process [8,9]. In the mid-1990s, most programs enabled the simulation of the forging process for pieces with axial symmetry and others, in which the flow of material could be approximated as occurring in only two dimensions [10].…”

“…The mesh size, type and number of elements will be informed by the software, and the data influence directly on the results presented by the simulation [8].…”