Fabrication Improvement of Cold Forging Hexagonal Nuts by Computational Analysis and Experiment Verification

Hsia, Shao‐Yi; Chou, Yu-Tuan

doi:10.1155/2015/835038

Cited by 10 publications

(5 citation statements)

References 11 publications

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“…According to different quality characteristics, various S / N ratio formulas are formed, including nominal-the-best, smaller-the-better and larger-the-better. The smaller-the-better was applied in this study for the optimization simulation to search for minimum wear, the S / N ratio [14,15] being:

S / N = - 10 log ({\bar{y}}^{2} + S_{n}^{2})

where y i is the measured value and n the number of repeated measurements.…”

Section: Research Methodology and Experimental Structurementioning

confidence: 99%

“…This was used as the evaluation standard for designing an upper punch and determining the strength of a die structure. Hsia and Chou [15] used computer simulations to analyze the fabrication of hexagonal nuts, and experimental metallography and hardness values were used to understand the cold forging characteristics of hexagonal nuts. Their research provided the information needed to understand forging loads and forming conditions at various stages before fastener formation.…”

Section: Introductionmentioning

confidence: 99%

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Wear Improvement of Tools in the Cold Forging Process for Long Hex Flange Nuts

Hsia

Shih²

2015

Materials

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Cold forging has played a critical role in fasteners and has been widely used in automotive production, manufacturing, aviation and 3C (Computer, Communication, and Consumer electronics). Despite its extensive use in fastener forming and die design, operator experience and trial and error make it subjective and unreliable owing to the difficulty of controlling the development schedule. This study used finite element analysis to establish and simulate wear in automotive repair fastener manufacturing dies based on actual process conditions. The places on a die that wore most quickly were forecast, with the stress levels obtained being substituted into the Archard equation to calculate die wear. A 19.87% improvement in wear optimization occurred by applying the Taguchi quality method to the new design. Additionally, a comparison of actual manufacturing data to simulations revealed a nut forging size error within 2%, thereby demonstrating the accuracy of this theoretical analysis. Finally, SEM micrographs of the worn surfaces on the upper punch indicate that the primary wear mechanism on the cold forging die for long hex flange nuts was adhesive wear. The results can simplify the development schedule, reduce the number of trials and further enhance production quality and die life.

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S / N = - 10 log ({\bar{y}}^{2} + S_{n}^{2})

where y i is the measured value and n the number of repeated measurements.…”

Section: Research Methodology and Experimental Structurementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Wear Improvement of Tools in the Cold Forging Process for Long Hex Flange Nuts

Hsia

Shih²

2015

Materials

Self Cite

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“…Forging is a process that changes the shape of metal via pressure to get desired mechanical properties, shapes, and sizes. Especially with the improvements in forging technology, complex parts like bolts and nuts can be formed with better mechanical properties and accurate dimensions [7]. For the bolt industry, cold forging is a favourable method since heating is unnecessary, surface precision is optimum, and the service life of the expensive dies can be preserved via cold forging [8].…”

Section: Introductionmentioning

confidence: 99%

Investigating the Effect of Heat Treatment on the Cold Forging of 27mnb4 Steel via Calphad Methodology and Fem

AKYILDIZ

Kutsal

ARSLAN>³

et al. 2023

Konya Journal of Engineering Sciences

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As a material forming method, cold forging is preferred due to the reasons like absence of a heating step and high surface quality. Recently, the finite element method (FEM) has received growing attention for controlling and predicting final material properties for cold forging applications. FEM combines microstructure evolution models with failure criteria, thus providing solutions to complicated problems in the modern cold forging industry. The fastener industry extensively utilizes cold forging, in which manganese and boron-containing steels like 27MnB4 can be formed to obtain high mechanical properties. The current study investigates the effect of two different heat treatments, namely softening and spheroidizing annealing, on the formability of 27MnB4 bolts. Softwares such as Thermo-Calc 2022a and Forge NxT 3.2 were used to predict the microstructure of the wire rod and evaluate the cold forming process of the same rod under two different heat treatment conditions. Therefore, the current study also provides a relationship between microstructural features and the cold formability of 27MnB4 steel. The microstructure of 27MnB4 is predicted by CCT diagrams. The predicted microstructure corresponds to the microstructure of 27MnB4 samples taken from the production line. In addition, temperature, von Mises stress, and equivalent strain distributions for 27MnB4 steel in the hot rolled state were calculated higher than in annealed states due to the differences in the microstructure. These results demonstrate that computational material engineering methods and simulation techniques could be practical tools for cold forming processes.

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“…Hsia et al [6] analyzed and simulated the forming load of each pass with finite element method and optimized product quality with Taguchi method at the critical second pass in 2014 to discuss the effects of various control factors under distinct standards. Deform-3D was also utilized for the simulation and analysis to induce the process parameter settings at the second pass during the minimal forming load.…”

Section: Introductionmentioning

confidence: 99%