Die System for Avoiding Thickness Reduction along the Bent Corner in Warm Plate Forging of an Axle Housing

Abstract

In this paper, a useful die system for warm plate forging of a large axle housing of heavy-duty trucks is presented. A die system composed of material flow guide pin as well as upper die and lower die is proposed to reduce the inherent thickness reduction along the bent corner of the product which deteriorates structural strength and fatigue life in its service. The role of the pin assembled in the upper die is to prevent formation of sharp corner in early forming stage and to supply material in the lower die cavity sufficient enough to thicken the bent corner at the final stroke. The mechanism of the die system is given and its effect on corner thickness of the product is revealed by two-dimensional finite element analysis under plain strain assumption. Three-dimensional finite element solutions are also given to verify validity of the two dimensional approach and to show the mechanics of the die system in detail. The die system has been successfully applied to manufacturing the axle housing of heavy-duty trucks.

Finite element analysis of a plate forging considering air-pocketing phenomena

“…Therefore, for many real situations, finite element simulations of metal-forming processes considering air-pocketing phenomena could be of great importance. The necessity of finite element simulations considering air-pocketing cannot be overemphasised, particularly in plate forging (Mori et al, 2011;Mori, 2012;Nakano, 2012;Orita, 2012;Kobayashi, 2012;Kim et al, 2010), for which applications have gradually increased. Here, plate forging refers to special forging of material with a large radius-to-thickness ratio that is not large enough to be considered sheet metal forming.…”