Abstract
Movable retaining pins are generally used in automobile gears, axles, crankshafts, and seatbelt assemblies. The original manufacturing procedures comprise three-stage forming and then drilling. However, a clamp in the drilling process always causes rod surface damage and dents, and the resulting depth tolerance that always exceeds specified dimensions. This study modifies the cold-forging process by replacing the original mechanical drilling stage with one additional forming stage comprised of backward extrusion. The finite element method is applied to analyze and simulate the forming load at each stage, and the Taguchi method is utilized to optimize the product quality in the key second stage. Analytical results show that transforming the original three forging processes and one drilling process into four forging stages overcomes the problems in part manufacturing. Simultaneously, the dimensional accuracy obtained from experiment and numerical analyses shows in good agreement and trusty.
Published Version
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