Blending Hierarchical Economic Decision Matrices (EDM) With FE and Stochastic Modeling: II — Detailing EDM

Abstract

The purpose of the Detailing EDM is to “fine-tune” a previously ameliorated design. First, in order to determine the best fillet radius for formability, forging simulations are conducted using commercial software. Once the fillet dimension is ascertained, the 3-D model is generated and maximum stresses determined for a trial force. Two different commercial programs were used to determine the three dimensional stresses. The only statistical quantities involve the loading (Gaussian distribution), the material “strength” in the Analytical Criteria for Failure (ACF), and possibly, the boundary conditions in the 3-D models. This paper considers the ACF to be the resistance to fatigue-fracture under complete reversal of loads at 5 × 108 cycles. The paper overviews three different methods of combining stochastic behaviour with FE analysis, and presents a methodology for using the interference-method with non-symmetrical distributions. The EDM are then presented for the three Product Criteria of forging — formability, Prime cost and 3-D reliability with respect to the selected ACF.

Key features and novel trends for developing cost engineering methods for forged components: a systematic literature review

“…Following the outcomes of the literature review, different considerations can be done. First of all, several works attempt to [111] FEM/FEA -CAM Forged part design and forging load Gear [112] FEM/FEA Component form errors-design, elastic analysis of part and die design Flywheel [44] CAE generic Forging load Axisymmetric components [70] CAE generic Energy consumption Not a specified type or shape [85] FEM/FEA Forging load, design of the part and design of the die Bevel gear [50] FEM/FEA Forging load and heating time Connecting road [100] FEM/FEA Forged part design Knuckle arm [120] FEM/FEA Forged part design Wheel [101] FEM/FEA Die design Not a specified type or shape [102] FEM/FEA Flow simulation and die design Not a specified type or shape [58] FEM/FEA Forging load and forged part design Bracket [84] FEM/FEA Forging load and forged part design Steering yoke [114] FEM/FEA Preform part design and forging load Aerofoil sections [115] FEM/FEA Die design Aerofoil sections [89] FEM/FEA Preform part design Bevel gear [119] FEM/FEA Forged part design Outer race [65] FEM/FEA Forged part design and forging load I-beam [108] CAE generic Forging load Axisymmetric components [123] FEM/FEA Preform die design H shaped parts cope with cost analysis in the forging industry covering a wide range of applications and related aspects (e.g. product geometries, process simulation, metallurgy, technology).…”

“…[115] [114] the engineering departments of manufacturing companies [44, 50, 58, 85, 100-102, 108, 114, 119, 123]. An interesting application of CAE for cost estimation was provided by developing commercial finite element software (DEFORM) to determine the best fillet radius for formability [58]. Several candidate processes (forging plus machining steps) were selected for evaluation in an economic decision matrix to define the best configuration (process) according to the cost.…”