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Design and Simulation of Forging Die Towards Improving Life of Closed Die

Akshay S. Nandalgaonkar, Sachin C. Borse

Abstract


Forging is the metal forming process which is used for forming complex shaped component with
geometrical accuracy. More than fifty percent of the forgings are processed through this way. Forged
components required in many engineering sectors, most of them in the automotive sector. The
majority of the safety critical component and load bearing structural components are process through
it. By using forging process production of complex component is faster with less material waste. It is
very difficult to do number of experimental testing and production trials are being done in the
industry in order to develop a strongly formed manufacturing process of complex component. Such
practices involve huge investment in tools and raw materials as well as valuable time and efforts. To
take the virtual trials and simulation-based design finite element method is best suitable tool. At lower
cost it would lead to improvement in life of die. As a sample case, a real-life automotive driveline
component like yoke, is taken for investigation. Based on finite element analysis simulation is dine in
Simufact. Different trials were done by using a forging press machine and validated against those
predicted in Simufact software. The relation between them was found to be similar and satisfactory. A
yoke is used in the propeller shaft of heavy vehicles is considered as a sample component. The
research involves analyzing the initial effects of (1) workpiece temperature, (2) friction, (3) die
temperature, and (4) Flash Thickness were examined. To obtained the results the forging process was
design in PTC Creo 3.0, simulated in Simufact Software and experimental setup and examined using
two-level full factorial design of experiments (Analyzed with Minitab and MS. Excel). The product
reviewed was at the Varsha Forging Waluj, Aurangabad.


Keywords


Die life improvement, Simufact, ANOVA, Taguchi, modeling

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References


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