An Analysis of Hot Forging Die Design Using the Finite Element Method
Date Issued
2005
Date
2005
Author(s)
Lin, Chia-Wei
DOI
zh-TW
Abstract
Due to keen competition in the forging products market, the forging companies are forced to respond to the market requirements by delivering a new product in a lead-time much shorter than that before. In order to cope with this dilemma, using CAE software to help the die design becomes a must for the forging industry. In the present study, the finite element software DEFORM with the Chinese graphic user interface was employed to analyze the hot forging process of manufacturing an automobile generator component, which is used as a holder of the coil. Since the coil holder bears a complex geometry with six claws extruded from the base, it cannot be produced by a single forging process, and in consequence, a preform is required to help the material flow in the subsequent forming process.
In the present study, the finite element analysis was first performed to examine the effect of the process parameters, such as blank dimension and friction condition, on the material flow in the performing process. The friction condition and the material flow in different performing processes were discussed, and an optimum blank height and die design were then determined from different strokes of upsetting forging based on the finite element simulation results. The production process with the proposed die design was also implemented. The sound product obtained in the production process validated the finite element analysis.
Due to the arising price of the steel, the material cost has been the major concern in the forging industry. In order to reduce the material cost, a closed-die forging process for producing a nearly net shape of the coil holder was proposed. According to the simulation results, the blank weight could be reduced from 1.5kg to 1.1kg, and the yield rate of the product increased from 60% to 81%. The methodology of computer-aided die design for the hot forging process developed in the present study could be applied to other forging products. The received results of this study could also be the reference resources for related academic research and be used to develop related products for the factory manufacturing.
Subjects
熱鍛模具設計
電腦輔助工程分析(CAE)
DEFORM軟體
閉模鍛造
hot forging
finite element method
die design
closed-die forging
Type
thesis
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