Numerical Simulation using Finite Elements to Develop and Optimize Forging Processes

Abstract

Forging is one of the main processes used to manufacture metal components for a broad range of applications. This occurs mainly because forged products are highly reliable and present superior mechanical properties. However, lately the competitiveness of forged products has been threatened, since the difference between their superior performance and the performance resulting from other processes has lessened continuously. This has obliged the forging industry to invest in optimizing its processes, saving in raw materials and energy. In this context, the use of numerical simulation of the forging process has become an increasingly reliable tool in seeking this optimization. This study uses the commercial software QForm 3D, version 3.2.1.1, to analyse two forging processes, one by hot forging and one by cold. In the case of hot forging, work on a component with axial symmetry is looked at from which a gear is machined. Currently the part is forged in three stages based on an initial billet with a 7.0 kg mass. Forging is performed in a 40 NM mechanical press with an initial temperature of 1200°C. The hot forging process is optimized and this results in a saving of about 5% in material. In the cold forging case it is shown that the process, as designed, results in laps in the final part, and in possible tool failure due to excess load. In both cases, the material used is DIN 1.7131 (16MnCr5) steel.