Abstract
Wear phenomenon is considered as a predominant parameter in the forming processes causing the shorten tool life which in turn increases the production costs. In this study, wear depth of tool components for multi-stages of metal shell of spark plug (MSSP) manufacturing was analyzed using Archard's model with FE simulation software. The 3D geometry models were built using SolidWorks software then the models files were exported to Simufact forming software to do the settings of preprocess and FE analysis. The cylinder compression test and ring compression test were executed to get the flow stress and frictional factor respectively. Product parts dimensions, forging loads, effective stress, relative sliding velocity and contact pressure were solved and discussed. Subsequently to verify the analysis acceptance, the actual product parts measurements which obtained by coordinate measuring machine (CMM), were compared with the simulation results. It was found that the deviations of actual MSSP geometry dimensions less than (4%). Also verification is performed to forging loads at each stage which gives a good agreement between actual and FE simulation results. Finally, the wear depth of tool components were calculated for each stage using the FE software. Based on the results of wear depth from simulation and tolerance rages of actual product parts, tool service lives were predicted to find the productivities for each tool component. The results of FE simulation were compared with the CMM measurements for known productivities tool components from actual production line, which gives a good accuracy and acceptable agreement
Highlights
The most important parameters in metal forming industries are product quality, productivity and production cost, which are related with tool performance and tool service life
The results of the finite element simulation are compared with actual results such that the part dimensions of each forming stage in FE simulation are listed opposite the actual dimensions
As an actual status that is followed in production planning of most companies, every tool components has a specified range of productivity, which is considered as tool life limitation
Summary
The most important parameters in metal forming industries are product quality, productivity and production cost, which are related with tool performance and tool service life. R.S. Lee and J.L. Jou, (2003) [3] presented a study of numerical simulation method (DEFORM code) combine with Archard wear model to analyze the warm forging of automotive transmission outer race and the predicted results of the die wear conditions were obtained. Two cases of experimental observations were compared with numerical predictions to verify Archard’s wear model in bulk deformation of metal forming processes. It can be established from the results that the wear depth increases as the wall thickness ratio increases and severe wear occurs in regions near the punch or mandrel corner. Liang D., et al, (2016)[10] used FEM as a base to solve tool wear and to investigate the contact
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have