Abstract
In this paper, we present a study on the development of the manufacturing process of thrust washers for an automobile. The thrust washers are manufactured using the progressive cold forging method. The proposed progressive cold forging method requires less manufacturing cost and processing time compared with the previous conventional manufacturing method, through the elimination of some cutting and grinding processes. The proposed cold forging method uses the single plate material that is used in multi-step forging process (progressive method). In order to estimate the plastic deformation of the product due to cold forging, we conduct a finite-element analysis and compare the predicted deformation with the experimental results. The effectiveness of the proposed manufacturing process is verified by comparing the simulation and experimental results. Finally, we suggest a new stereotyped design of the single plate type cold forging process, based on the data obtained by performing simulation and experiments.
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