Abstract
Finite element method and experiments have been used to study a cold forming method for fabrication of a flange using the effect of billet preforming. Three dimensional finite element methods carried out to obtain the forming load, die filling, material flow, effective stress, effective strain with DEFORM-3D software, and a series of experimental works has been performed using lead metal with four types of billet preforming in the first stage. Pressing process has been done using computerized hydraulic press machine with 100 tons. The forming sequence is carried out in two stages. In the first stage, the cylindrical billet is preformed by upsetting and in the second stage forming it in a die. Results indicate that the process of formation is influenced by preforming of billet with fixed volume in the final stage of pressing, improve the mechanical properties of the metal and thus facilitates the final deformation process with less stress and better flow of the metal inside the die. Simulation results show that the effective stress, maximum principal stress, effective strain, velocity and damage are maximum at locations where flange open out and rib growth begins across the geometrical interlocking between the two halves of die-set and the component surface.
Highlights
Metal forming is one of the prime mode for forming the metals into useful form through application of forces
Flow simulation of the precision forming process carried out had been provided critical results which gives a detailed description of the effective stress, stress Max. principal, effective strain, velocity and damage analysis of the component as well as die set used in the process
The careful observation of the results shows that the effective stress, maximum principal stress, effective strain, velocity and damage are maximum at locations where flange opens out and rib growth begins across the geometrical interlocking between the two halves of die-set and the component surface
Summary
Metal forming is one of the prime mode for forming the metals into useful form through application of forces. Bulk metal forming includes processes such as extrusion, rolling, drawing and forging etc. Mechanical forming operations include all forming operations that take place on the metals and alloys in solid case without any melted. All these processes go on under the influence of mechanical forces by using special equipment and hardware that are securing these powers and bring about the change required in the forms or metal bodies, alloys that can performed these operations either cold or hot[2]. The ability of metals and alloys to any change in the shape by effect of mechanical forces related with structure and the crystal lattice of the metal. The purpose of this paper is to analyze the problem of die filling, press load, stress analysis and material flow to obtain a final product of the flange free from defects
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