Abstract
In this paper, Finite Element method and full-scale experiments have been used to study a hot forging method for fabrication of a spindle using reduced initial stock size. The forging sequence is carried out in two stages. In the first stage, the hot rolled cylindrical billet is pre-formed and pierced in a closed die using a spherical nosed punch to within 20 mm of its base. This process of piercing or impact extrusion leads to high strains within the work piece but requires high press loads. In the second stage, the resulting cylinder is placed in a die with a flange chamber and upset forged to form a flange. The stock mass is optimized for complete die filling. Process parameters such as effective strain distribution, material flow and forging load in different stages of the process are analyzed. It is concluded from the simulations that minor modifications of piercing punch geometry to reduce contact between the punch and emerging vertical walls of the cylinder appreciably reduces the piercing load. In the flange chamber, a die surfaces angle of 52° instead of 45° is proposed to ensure effective material flow and exert sufficient tool pressure to achieve complete cavity filling. In order to achieve better compression, it is also proposed to shorten both the length of the inserted punch and the die “tongues” by a few mm.
Highlights
A forging company in the middle of Sweden designs, manufactures, and distributes forged and machined components for the heavy truck industry and engineering industry
It is concluded from the simulations that minor modifications of piercing punch geometry to reduce contact between the punch and emerging vertical walls of the cylinder appreciably reduces the piercing load
Modifying the punch geometry to minimize the contact between the punch and the vertical wall of the emerging cylinder will appreciably bring down the press load
Summary
A forging company in the middle of Sweden designs, manufactures, and distributes forged and machined components for the heavy truck industry and engineering industry. The company forges and machines cylinder components, boring bits, and twist lock pins for container lifting. It’s subjected to a series of different forgings and later machined to the final geometry which weighs about 13 kg. This manufacturing route is not cost effective since it leads to about 22% of the initial weight as waste. The flange which is the critical part of the components, is machined rather than forged
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