Abstract
Numerous forms and manufacturing methods of bicycle pedals exist in current markets. The purpose of this study was primarily to design an innovative forging die for a bicycle pedal company through a simulative analysis, using commercial finite element package software. A series of simulation analyses adopted workpiece temperature, mold temperature, forging speed, friction factor, and size of the mold as variables to evaluate the methods of lightweight in the bicycle pedal forging press. The study involved modifying professional bicycle pedal sizes. The effective strain, effective stress, and die radius load distribution of the pedals were analyzed under various forging conditions. Aluminum (A6061 and A7075) was used to analyze the simulative data. The optimal control parameters were subsequently obtained using the Taguchi methods and a genetic algorithm. The results of the simulation analyses indicated that the design of an experimental forging die can lower the deformation behavior of a bicycle pedal.
Highlights
Progress in precision forging technology, including low production costs and rapid production, has allowed for the intensive use of forging
Zhao et al [6] improved the microstructure and properties of hot isostatic pressed Ti-17 power compact through isothermal forging with preferable deformation parameters that were provided by a processing map
The Taguchi method, a well-known robust design technique, provides comprehensive understanding of the individual and combined effects of various design parameters based on a minimal number of experimental trials
Summary
Progress in precision forging technology, including low production costs and rapid production, has allowed for the intensive use of forging. Wang et al [1] developed a practical compliance control method for hydraulic forging manipulators. A hybrid force-position control method was proposed and performed on a novel serial-parallel forging manipulator. Wang et al [3] improved the two-stage extrusion process and related die designs of a forging company that currently manufactures a support shaft by using the traditional method. Narayanasamy et al [4, 5] evaluated aspects of extrusion forging during cold upsetting by using a suitable die and aluminum alloy (H9-6063) solid cylinders that were subjected to various geometrical conditions. Zhao et al [6] improved the microstructure and properties of hot isostatic pressed Ti-17 power compact through isothermal forging with preferable deformation parameters that were provided by a processing map
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