Abstract
Rotary hammer forging process is getting popular since it has many advantages comparing to the conventional forging process. The mechanism of the movement in term of orbital motion of the conical upper die become concern of this research. This article present the three stages of the modelling of the rotary hammer forging. The first stage is the development of the orbital motion of the conical upper die. Three-dimensional CAD model of the conical upper die was developed to determine the orbital motion as a function of the four parameters: Nutation, Precession, Spin and Rocking-Die mechanism. A reasonably accurate design of the conical upper die and the workpiece had been developed based on motion because of interaction of conical upper die and upper part of workpiece geometries. The behaviour of orbital motion with any active combination of those four parameters was observed. The second stage was the development of the conical upper die with the specific feature in order to generate a product with an unsymmetrical shape of upper part of the product. The sequence and mechanism of the formation of the upper part of product were generated. The third stage was the analysis of the stress strain state during the formation of the upper part of the workpiece. An elastic-plastic, dynamic analysis of 3D rotary hammer forging mechanism with the concern at the workpiece and their interaction with a model of dies have been performed. Verification of the indentation mechanism of the rotary hammer forging had been done by validating the result with the existing experimental results.
Highlights
1 INTRODUCTION Rotary Hammer Forging is one type of forging process which is called as Wobble Die Forging
The objective of this research is to develop a new method as a framework to design forging process as well as die design in a rotary hammer forging
The research hypotheses on guidelines to the development of analytical and numerical model of the rotary hammer forging are as follows: 1. There is no unique way for the formation of profile indented to the upper part of workpiece
Summary
Parts that have circular feature such as bearing housing, gears, chain sprocket, coupling and clutch hubs are produced by this process. To be competitive, the processes are to be faster and accurate method on designing forging mechanism as well as the dies [1, 2, 3]. In this quite competitive era in the business, product life cycle should be shorter to be competitive. Is there any standard guideline to design the conical upper die of a rotary hammer forging? Which friction model is suitable in modelling interaction between workpiece and upper conical and lower die?
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