Finite Element Modeling of Shrink-Fit Design for Improvement of Die-Service Life in Hot Forging Process of a Bevel Gear

Soranansri, Panuwat; Yanil, Surawut; Sirivedin, Kumpanat

doi:10.1016/j.matpr.2019.06.202

Cited by 11 publications

(4 citation statements)

References 12 publications

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“…Within the scope of the study, each step of the towing hook forging process is planned. Simulation studies have been performed for the new die design in Q-Form, which is working with the finite element analysis principle [7,8]. Characterization studies were carried out, tensile and hardness tests were carried out.…”

Section: Resultsmentioning

confidence: 99%

Development of New Die Design in Towing Hook Production

SAĞ>¹,

BAHAT>

YALÇIN>³

et al. 2022

International Journal of Advances in Engineering and Pure Sciences

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In this study, a new design has been developed for towing hook dies used in hot forging processes. For this objective, analysis studies were carried out with different process parameters and methods for new designs in dies for both hot forging process and product. After the analysis, the die designs were determined that produced the prototype products at the optimum speed, efficiency and quality. While designing a special die for hot forging operation, a new die design has been developed in which both processes can be performed using a single die with two stages, pre-shape and final shape. Compared to the dies studied for hook groups in the literature and our old dies currently being worked, it is aimed to eliminate the errors caused by the inability to calibrate the final shape such as early wear, short die life, burr residue formation. Such a technics specific to the part as specific to the towing hook was performed for the first time, and with the die design developed by comparing the results of analysis studies, field trials and prototype studies in the Q-Form simulation program, the production of towing hook at optimum efficiency was achieved.

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Section: Resultsmentioning

confidence: 99%

Development of New Die Design in Towing Hook Production

SAĞ>¹,

BAHAT>

YALÇIN>³

et al. 2022

International Journal of Advances in Engineering and Pure Sciences

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“…This said, we sometimes observe overheating or cooling of the tools during forging, which points to an insufficiently worked-out technology. In such a case, it is crucial to "steer" the lubrication process, meaning to increase or decrease the lubricant dose or change the lubricating technique [11]. The formation of the lubricating film depends on the spreading of the lubricant droplets (graphite in water) and their drying.…”

Section: Introductionmentioning

confidence: 99%

Selected Aspects of Lubrication in Die Forging Processes at Elevated Temperatures—A Review

Hawryluk,

Dudkiewicz,

Marzec

et al. 2023

Lubricants

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The paper concerns selected aspects of the application of cooling–lubricating agents as well as methods and devices assigned to lubrication in hot die forging processes realized at elevated and high temperatures in the context of their effect on the quality of the forgings and the durability of the forging instrumentation. An analysis was made of the currently used lubricants and their properties and applications in selected industrial forging processes, and a review was conducted of the presently applied cooling–lubricating systems and devices. The article also presents the authors’ own studies referring to the effect of the application of lubricating and cooling agents, the volume of the lubricant portion, the times and directions of its application, and other factors affecting tribological conditions. It also presents lubricating devices constructed based on the knowledge and experience of the authors. The elaborated systems, introduced into selected forging processes, make it possible to examine the effect of the volume and time-frequency of the applied lubricant dose on the wear of the tools and also to select and ensure the optimal tribological conditions in the process with respect to durability. The obtained research results, which were confirmed in the industrial process, indicate the great potential of implementing such devices also in other forging processes because the proposed solutions ensure greater repeatability and stability of working conditions. This increases the efficiency of production and thus significantly reduces the unit production costs, as a two-fold increase (from 8000 to 16,000 forgings) in tool life has been observed.

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“…McCormack and Monaghan [ 10 ] proposed the most suitable die design for manufacturing hexagon head bolts by analyzing the forming results with respect to the head angle using FEA. Soranansri et al [ 11 ] designed a die with an appropriate shrink fit, which was used to improve die life, to manufacture bevel gears using forging.…”

Section: Introductionmentioning

confidence: 99%

Multi-Stage Cold Forging Process for Manufacturing a High-Strength One-Body Input Shaft

Jeong

Lee

et al. 2021

Materials

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A multi-stage cold forging process was developed and complemented with finite element analysis (FEA) to manufacture a high-strength one-body input shaft with a long length body and no separate parts. FEA showed that the one-body input shaft was manufactured without any defects or fractures. Experiments, such as tensile, hardness, torsion, and fatigue tests, and microstructural characterization, were performed to compare the properties of the input shaft produced by the proposed method with those produced using the machining process. The ultimate tensile strength showed a 50% increase and the torque showed a 100 Nm increase, confirming that the input shaft manufactured using the proposed process is superior to that processed using the machining process. Thus, this study provides a proof-of-concept for the design and development of a multi-stage cold forging process to manufacture a one-body input shaft with improved mechanical properties and material recovery rate.

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Finite Element Modeling of Shrink-Fit Design for Improvement of Die-Service Life in Hot Forging Process of a Bevel Gear

Cited by 11 publications

References 12 publications

Development of New Die Design in Towing Hook Production

Development of New Die Design in Towing Hook Production

Selected Aspects of Lubrication in Die Forging Processes at Elevated Temperatures—A Review

Multi-Stage Cold Forging Process for Manufacturing a High-Strength One-Body Input Shaft

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