Recent advances in cold and warm forging process modeling techniques: selected examples

Abstract

The key to survival in today's competitive market is manufacturing high quality products at low cost. In the context of metal forming, this translates into fewer and more efficient processes, elimination of secondary operations, while maintaining the surface finish, tolerance and dimensional specifications. Making the right choice of a process that is cost-effective for the required production volume and yet meets the design requirements, is extremely important. One approach to achieving this objective is through process modeling for net shape manufacturing. This paper presents ongoing industry relevant research at the Engineering Research Center in the area of cold and warm forging towards better quality and lower cost. It reports current research on sequence design for fuel injector nozzle, modeling of fracture during induction heating, modeling of warm/hot forging of microalloyed steels and development of an integrated process planning system. These efforts could result in reduced process defects and lower process costs.