Development of a flexible tool system for small quantity production in cold forging

Nielsen, Lise Skovsgaard; Lassen, S.; Andersen, Claus Bo; Grønbæk, J.; Bay, Niels

doi:10.1016/s0924-0136(97)00140-4

Cited by 18 publications

(8 citation statements)

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“…Four different cold forming tests were planned (figure 5): (i) compression of rectangular blocks, for analysing material flow behaviour under flattening conditions, (ii) heading of slender cylindrical billets, for assessing buckling deformation modes under axial compression, (iii) reduction of the cross-section of bars, in order to examine material flow behaviour under fullering conditions and (iv) forging of spur gear parts, for investigating material flow in a nett-shape forming operation. The material used in all the experiments was a E1CM aluminium (99.95%) and the flexible cold forming tool system operated during the experiments is shown in figure 6 [20]. Experiments were performed on a 1.6 MN computer-controlled hydraulic press and carried out at a constant punch velocity at room temperature.…”

Section: Methodsmentioning

confidence: 99%

Simulation of three-dimensional bulk forming processes by finite element flow formulation

Alves

Rodrigues

Martins

2003

Modelling Simul. Mater. Sci. Eng.

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This paper focuses from the fundamentals of finite element flow formulation to the main aspects of computer implementation and modelling of three-dimensional bulk forming processes. Fundamental research and development is based on a comprehensive analysis of a wide range of theoretical and computational subjects such as selection of elements, solution procedures, contact algorithms, and meshing and remeshing procedures. We also focus on elastic analysis of tooling and a simple algorithm is proposed for transferring the load across the die–workpiece contact interface.The overall study is supported by several specially designed, cold forming experimental parts that were manufactured under laboratory-controlled conditions. Comparisons between theoretical predictions and experimental results comprise a wide range of topics such as material flow, geometry, forming load and strain distribution.

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Section: Methodsmentioning

confidence: 99%

Simulation of three-dimensional bulk forming processes by finite element flow formulation

Alves

Rodrigues

Martins

2003

Modelling Simul. Mater. Sci. Eng.

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“…Enabling flexibility of production: To maintain the required flexibility, at the same time, to maintain low tool-cost, a flexible-tool system was developed [18], which enables to operate with any of eight basic cold-forging processes, by changing only a few components, such as the punch, die and ejector, whereas all other parts are standard. Another flexible tool-system is that for the forming of camshafts and similar forms with hydroforming set-up [19].…”

Section: Article In Pressmentioning

confidence: 99%

Forming-tool design innovation and intelligent tool-structure/system concepts

Qin

2006

International Journal of Machine Tools and Manufacture

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“…Experiments were carried out at a constant punch velocity of 4.3 mm/s on a computer-controlled 2500 kN hydraulic press. They were based on the utilization of an already existing versatile tool [46], for which supplementary tool components were designed and manufactured. Extrusion force was measured by a load transducer mounted on the moving traverse, connected to the punch.…”

Section: Equipment and Processmentioning

confidence: 99%

Friction measurement and modelling in forward rod extrusion tests

Tan

Bay

Zhang

2003

Proceedings of the Institution of Mechanical Engineers, Part J:

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Forward extrusion is one of the important processes in bulk metal forming. Friction stress can be estimated from the slope of the load-displacement curve at the steady state after the maximum load in a forward extrusion test. In this paper, forward rod extrusion tests are carried out to determine experimentally friction stress at various normal pressures, reductions in area, billet heights and lubrications. Tested materials include aluminium alloy, low carbon steel and stainless steel. Two lubrication methods are applied, conversion coating followed by either alkaline soap or molybdenum disulphide as the lubricant. Friction stresses are obtained from measurements of slopes of extrusion pressure-punch travel curves at the steady state stage. Normal pressures are evaluated by using Mohr's circle, in which shear flow stresses are estimated at the maximum elastic deformation points from the same extrusion pressure-punch travel curves. It is found that the relationship between normal pressure and friction stress appears linear, and therefore Coulomb's friction model fits the experimental data very well. Extrusion pressure-punch travel curves before the steady state can be divided into four stages: elastic deformation, filling container deformation, filling die aperture deformation and exiting inhomogeneous deformation.

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Development of a flexible tool system for small quantity production in cold forging

Cited by 18 publications

References 0 publications

Simulation of three-dimensional bulk forming processes by finite element flow formulation

Simulation of three-dimensional bulk forming processes by finite element flow formulation

Forming-tool design innovation and intelligent tool-structure/system concepts

Friction measurement and modelling in forward rod extrusion tests

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