Abstract
Cold forging has played a critical role in fasteners and has been widely used in automotive production, manufacturing, aviation and 3C (Computer, Communication, and Consumer electronics). Despite its extensive use in fastener forming and die design, operator experience and trial and error make it subjective and unreliable owing to the difficulty of controlling the development schedule. This study used finite element analysis to establish and simulate wear in automotive repair fastener manufacturing dies based on actual process conditions. The places on a die that wore most quickly were forecast, with the stress levels obtained being substituted into the Archard equation to calculate die wear. A 19.87% improvement in wear optimization occurred by applying the Taguchi quality method to the new design. Additionally, a comparison of actual manufacturing data to simulations revealed a nut forging size error within 2%, thereby demonstrating the accuracy of this theoretical analysis. Finally, SEM micrographs of the worn surfaces on the upper punch indicate that the primary wear mechanism on the cold forging die for long hex flange nuts was adhesive wear. The results can simplify the development schedule, reduce the number of trials and further enhance production quality and die life.
Highlights
The widespread use of fasteners reflects their importance in various industries
Product innovation is increasingly difficult owing to price competitiveness from China and Southeast Asian countries and to the increasing complexity of emerging products
With comprehensive curriculum planning and the introduction and training of operating skills, the practical experiences of designers are combined with a theoretical knowledge of graphics and simulation software, which is cross-referenced and mutually verified to improve a project
Summary
Taiwan exported roughly 1.46 million tons of fasteners in 2013, with gross revenues reaching U.S $4 billion to rank fifth in global fastener production. Both the quantity and the quality of fasteners from Taiwan contribute significantly to international markets. With comprehensive curriculum planning and the introduction and training of operating skills, the practical experiences of designers are combined with a theoretical knowledge of graphics and simulation software, which is cross-referenced and mutually verified to improve a project. Peer involvement stimulates manufacturing skills, simplifies the product development schedule, reduces overhead costs and increases industrial competitiveness
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