Abstract
The process of precision forging has been developed recently because of its advantages of giving high production rates and improved strength. For complete filling up, predicting the power requirement and final shape are important features of the forging process. A finite element method is used to investigate the forging force, the final shape and the stress distribution of the parking sensor shell forging. The stress-strain curve of AL-6082 is obtained by the computerized screw universal testing machine. The friction factor between AL-6082 alloy and die material (SKD11) are determined by using ring compression test. Stress-strain curve and fiction factor are then applied to the finite element analysis of the parking sensor shell forging. Maximum forging load, effective stress distribution and shape dimensions are determined of the parking sensor shell forging, using the finite element analysis. Then the parking sensor shells are formed by the forging machine. Finally, the experimental data are compared with the results of the current simulation for the forging force and shape dimensions of the parking sensor shell.
Highlights
Parking sensors are proximity sensors for road vehicles designed to alert the driver to obstacles while parking
The friction factor between AL-6082 and die material are determined by using ring compression test
Stress-strain curve and fiction factor are applied to the finite element analysis of the parking sensor shell forging to predict the forging force and the shape of parking sensor
Summary
Parking sensors are proximity sensors for road vehicles designed to alert the driver to obstacles while parking. Khaleed et al [5] performed three-dimensional analysis including thermal effects for a flash-less cold forging product of aluminum alloy. They obtained a good agreement with experimental results and optimized the initial shape of the workpiece. This study development the aluminum alloy forging process and die design of parking sensor shell. The friction factor between AL-6082 and die material are determined by using ring compression test. Stress-strain curve and fiction factor are applied to the finite element analysis of the parking sensor shell forging to predict the forging force and the shape of parking sensor. The experimental data are compared with the results of the current finite element simulation
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