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

Hsia, Shao‐Yi; Shih, Po-Yueh

doi:10.3390/ma8105328

Cited by 25 publications

(13 citation statements)

References 17 publications

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“…1 shows the transparent three-dimensional chart of the die for successive extrusion processing, including a billet, ram, container, and die. The figure is of a single element that is first transformed into an STL file and then DEFORM-3D forming software is used [14,15]. Fig.…”

Section: Methodsmentioning

confidence: 99%

A Numerical Simulation of Meshes Mending Used in the Three-dimensional Porthole Die Extrusion of Thin Wall Profiles

Hsia

2018

JERR

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Aims: The variety of aluminium products used in many industries (e.g., aviation, railroad, and transport) drive the need for an urgent increase in aluminium feedstock. Improved aluminium extrusion forming and mold design guarantee product quality, shorten production time, and enhance mold life. We analyse and discuss the problems resulting from the simulation and analysis of thin-layer aluminium alloy rims by focusing on porthole die extrusion for bicycles. In general, when analysing with CAE, the billet going from portholes to the welding chamber in the hot extrusion forming process indicates that mesh penetration during remesh causes volume loss and stops the simulation. This is especially serious on thin wall products. Methodology: In this study, applying mesh mending to extrusion of the billet could solve this problem, and the previous issue of mesh contact causing volume disappearance would not appear during simulation. After solving the remesh problem, the optimisation method in the Taguchi Method could be utilised to modify the hot extrusion mold and analyse its existing speed to avoid uneven forming. Results: Our analysis simultaneously examined stress, strain, velocity gradient, and product formation to understand the relationships between parameters and extrusion load as well as forming defects caused by thin wall extrusion. It is expected to provide a specifically practicable analysis model for aluminium extrusion. Conclusion: Comparing the simulation size with design size ensures accuracy. The maximum size error was 8.70% at a size of 0.92mm, and the maximum error of the rest of the sizes was about ±5%, which was acceptable in this study.

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Section: Methodsmentioning

confidence: 99%

A Numerical Simulation of Meshes Mending Used in the Three-dimensional Porthole Die Extrusion of Thin Wall Profiles

Hsia

2018

JERR

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“…The friction coefficient of the PTFE foil used in experimental work was determined with a standardized ring upsetting test [30,31]. According to the well-known diagram with calibration curves for various Coulomb's friction coefficients µ the applied foil expressed a friction value between µ = 0.03 and µ = 0.04 [32].…”

Section: Fem Modelmentioning

confidence: 99%

Upsetting Analysis of High-Strength Tubular Specimens with the Taguchi Method

Pepelnjak¹,

Šašek

Kudláček

2016

Metals

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Abstract:In order to obtain input data for numerical simulations of tube forming, the material properties of tubes need to be determined. A tube tensile test can only be used to measure yield stress and ultimate tensile stress. For tubes with a large diameter/thickness ratio (D/t), tensile specimens are cut out and processed in a similar way as with sheet metal. However, for thin tubes with a diameter/thickness ratio below 10, the tensile specimens could not be cut out. The flow curve of the analyzed tube with a small diameter and D/t ratio of 7 was determined with a ring-shaped specimen. The experimental force-travel diagram was acquired. A reverse-engineering method was used to determine flow curves by numerical simulations. Using an L 25 orthogonal array of the Taguchi method different flow curve parameters and friction coefficient combinations were selected. Tube upsetting with determined parameter combinations was performed with the finite element method. With analysis of variance influential equations among selected input parameters were determined for the force levels at six upsetting states. With the evaluation of known friction coefficients and flow curve parameters, K, n, and ε 0 according to the Swift approximation were determined and proved by the final shape of the workpiece.

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“…However, this high flow stress requires a high load and only a limited variety of shapes can be produced. Hence, the cold forging process alone, or one combined with hot forging, has been previously used [ 2 , 3 , 4 , 5 , 6 ]. Fujikawa et al [ 7 ] described a method for combining warm and cold forging to manufacture constant-velocity joints and spline shafts for automobiles.…”

Section: Introductionmentioning

confidence: 99%

Multi-Stage Cold Forging Process for Manufacturing a High-Strength One-Body Input Shaft

Jeong

Lee

et al. 2021

Materials

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A multi-stage cold forging process was developed and complemented with finite element analysis (FEA) to manufacture a high-strength one-body input shaft with a long length body and no separate parts. FEA showed that the one-body input shaft was manufactured without any defects or fractures. Experiments, such as tensile, hardness, torsion, and fatigue tests, and microstructural characterization, were performed to compare the properties of the input shaft produced by the proposed method with those produced using the machining process. The ultimate tensile strength showed a 50% increase and the torque showed a 100 Nm increase, confirming that the input shaft manufactured using the proposed process is superior to that processed using the machining process. Thus, this study provides a proof-of-concept for the design and development of a multi-stage cold forging process to manufacture a one-body input shaft with improved mechanical properties and material recovery rate.

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

Cited by 25 publications

References 17 publications

A Numerical Simulation of Meshes Mending Used in the Three-dimensional Porthole Die Extrusion of Thin Wall Profiles

A Numerical Simulation of Meshes Mending Used in the Three-dimensional Porthole Die Extrusion of Thin Wall Profiles

Upsetting Analysis of High-Strength Tubular Specimens with the Taguchi Method

Multi-Stage Cold Forging Process for Manufacturing a High-Strength One-Body Input Shaft

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