FEM analysis of manufacturing of a hollow product with an outer flange in a four-stage cold forming process

Abstract

The paper presents the results of a FEM computer simulation of the cold forming process of a hollow sleeve forgings with an outer flange. Numerical simulations were carried out in DEFORM 2D / 3D. For the numerical calculations of the forming process the axisymmetric calculation module was used. As the test object, a tubular workpiece with an outer diameter of Ø50 mm and a wall thickness of 10 mm made of 42CrMo4 steel was used. The process of forming the rotary sleeve was conducted in four stages consisting of two technologies. The first stage of the research was the analysis and selection of parameters of the extrusion process, which was used for the first stage of forming. The processes of free extrusion and the use of a container were analysed. Furthermore different die angles and different wall thickness reductions were used. The products obtained in the extrusion process were upset in three conical blanks. The aim of the study was to analyse the numerical accuracy of the designed process of forming the hollow shaft with flange. The analysis of the results was based on the deformation intensity distribution maps, the Cockroft-Latham criterion distribution and the progress of the forming forces. On the basis of the conducted research, it was concluded that the presented process of forging a hollow product with a flange in four stages is possible to carry out correctly.