Abstract
Finite Element Method based techniques apply to a wide spectrum of engineering applications including manufacturing. The flexibility to achieve optimized results by simulations adds another dimension to process-development. The efficiency due to simulation is enhanced many folds for developing desired components by reducing the cost as well as time. This paper investigates cold forging process to be adopted to produce camshafts with a target to minimize flash as well as under filling. These two factors being major problems encountered when cold forging is to be adopted for complex shaped products. The current work is primarily concerned with the development of an optimized preform design for a V8 engine camshaft. The work involved the Solid modeling of the camshaft on AutoCAD and further analyzing the developed model through finite element analysis using Deform 3D. The analysis involved understanding of metal flow, volumetric analysis and die stresses in the forging process. The materials considered for the work-piece and the dies are AISI 8620 and AISI-H-26 respectively. The sample camshaft was taken from a standard Dodge Challenger V8 engine. 10 different cases are analyzed to find out the best possible scenario. It is fund that the stress level for the developed model was very much within the design limit of the material.
Highlights
Forging involves deformation of materials under compressive stress and it can be categorized on the basis of temperature of the work-piece
This section deals with the methodology adopted for preparation and implementation of the finiteThis element approach forthe themethodology analysis of cold forging a V8 engine
The pivotal matter of interest in the present work was to check the feasibility of producing camshafts involving cold forging techniques
Summary
Forging involves deformation of materials under compressive stress and it can be categorized on the basis of temperature of the work-piece. In a study by Kim et al [4] the numerical simulations using DEFORM-3D/HT were applied to several design stages in cold forging and heat treatment of the helical gear for the automotive steering part. It was found from the simulation results that CAE could be used as an effective and strong tool to improve process design, such as modification of forming defect during forging process, improvement of tool life, and predictions of microstructure and dimensional change during heat treatment after forging. They revealed that a very narrow range billet dimensions exists for acceptable hollow ball forging
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