An Analysis of Hot Forging Die Design Using the Finite Element Method
|關鍵字:||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||公開日期:||2005||摘要:||由於國內外鍛品市場之蓬勃發展，鍛造業者面臨到鍛品品質之要求，以及在納期縮短方面均較以往嚴苛，所以利用電腦輔助工程分析（Computer-Aided Engineering，CAE）已是刻不容緩的課題。本研究選用DEFORM軟體做為分析軟體，輔以實驗室自行開發之中文化介面，選擇目前國內熱鍛產品之一的汽車交流發電機之磁座作為載具進行模具設計之分析。
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.
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