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1
Mao, Yongning. "Forging Process Design for Risk Reduction." The Ohio State University, 2009. http://rave.ohiolink.edu/etdc/view?acc_num=osu1237565667.
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Ozturk, Huseyin. "Analysis And Design For Aluminum Forging Process." Master's thesis, METU, 2008. http://etd.lib.metu.edu.tr/upload/12610270/index.pdf.
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Aluminum forging products has been increasingly used in automotive and aerospace industry due to their lightness and strength. In this study, aluminum forging processes of a particular industrial part for the two different alloys (Al 7075 and Al 6061) have been analyzed. The forging part, forging process and the required dies have been designed according to the aluminum forging design parameters. The proposed process has been simulated by using the Finite Volume Method. In the simulations, analysis of the part during forging process has been performedand the required forging force, the temperature distribution and the effective stress distribution in the parts have been obtained. The forging dies were produced in the METU-BILTIR Center CAD/CAM Laboratory. The experimental study has been performed in the METU-BILTIR Center Forging Research and Application Laboratory. The parts were produced without any defects as obtained in the finite volume simulations. The results of the experiment and finite volume simulation are compared and it has been observed good agreement.
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Sarac, Sevgi. "Design And Thermo-mechanical Analysis Of Warm Forging Process And Dies." Master's thesis, METU, 2007. http://etd.lib.metu.edu.tr/upload/12608826/index.pdf.
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Forging temperature is one of the basic considerations in forging processes. In warm forging, the metals are forged at temperatures about the recrystallization temperature and below the traditional hot forging temperature. Warm forging
has many advantages when compared to hot and cold forging. Accuracy and surface finish of the parts is improved compared to hot forging while ductility is increased and forming loads are reduced when compared to cold forging. In this study, forging process of a part which is currently produced at the hot forging temperature range and which needs some improvements in accuracy, material usage and energy concepts, is analyzed. The forging process sequence
design with a new preform design for the particular part is proposed in warm forging temperature range and the proposed process is simulated using Finite Element Method. In the simulations, coupled thermal mechanical analyses are performed and the dies are modeled as deformable bodies to execute die stress analysis. Experimental study is also carried out in METU-BILTIR Center Forging Research and Application Laboratory and it has been observed that numerical and experimental results are in good agreement. In the study, material wastage is reduced by proposing using of a square cross section billet instead of a circular one, energy saving and better accuracy in part dimensions is achieved by reducing the forging temperature from the hot forging to the warm forging temperature range.
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Vemuri, Koteswara Rao. "A knowledge-based approach to automate geometric design with application to design of blockers in the forging process /." The Ohio State University, 1986. http://rave.ohiolink.edu/etdc/view?acc_num=osu1487323583622657.
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Mahmood, Tariq. "Knowledge-based process planning and design system for the cold forging of steel." Thesis, Imperial College London, 1991. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.264352.
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Ozgen, Arda. "Cutting Strategies For Forging Die Manufacturing On Cnc Milling Machines." Master's thesis, METU, 2008. http://etd.lib.metu.edu.tr/upload/12609433/index.pdf.
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Manufacturing of dies has been presenting greater requirements of geometrical accuracy, dimensional precision and surface quality as well as decrease in costs and manufacturing times. Although proper cutting parameter values are utilized to obtain high geometrical accuracy and surface quality, there may exist geometrical discrepancy between the designed and the manufactured surface profile of the die cavities. In milling processcutting speed, step over and feed are the main cutting parameters and these parameters affect geometrical accuracy and surface quality of the forging die cavities. In this study, effects of the cutting parameters on geometrical error have been examined on a representative die cavity profile. To remove undesired volume in the die cavities, available cutting strategies are investigated. Feed rate optimization is performed to maintain the constant metal removal rate along the trajectory of the milling cutter during rough cutting process. In the finish cutting process of the die cavities, Design of Experiment Method has been employed to find out the effects of the cutting parameters on the geometrical accuracy of the manufactured cavity profile. Prediction formula is derived to estimate the geometrical error value in terms of the values of the cutting parameters. Validity of the prediction formula has been tested by conducting verification experiments for the representative die geometry and die cavity geometry of a forging part used in industry. Good agreement between the predicted error values and the measured error values has been observed.
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Ozcan, Mehmet Cihat. "Thermo-mechanically Coupled Numerical And Experimental Study On 7075 Aluminum Forging Process And Dies." Master's thesis, METU, 2008. http://etd.lib.metu.edu.tr/upload/12610000/index.pdf.
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Combination of high strength with light weight which is the prominent property of aluminum alloy forgings has led aluminum forgings used in rapidly expanding range of applications.
In this study, to produce a particular 7075 aluminum alloy part, the forging process has been designed and analyzed. The forging process sequence has been designed by using Finite Volume Method. Then, the designed process has been analyzed by using Finite Element Method and the stress, strain and temperature distributions within the dies have been determined. Five different initial temperatures of the billet438, 400, 350, 300 and 250 degree Celsius have been considered in the thermo-mechanically coupled simulations. The initial temperatures of the dies have been taken as 200 degree Celsius for all these analyses. Finite volume analysis and finite element analysis results of the preform and finish part have been compared for the initial billet temperature of 400 oC. Close results have been observed by these analyses. The experimental study has been carried out for the range of the initial billet temperatures of 251&
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442 degree Celsius in METU-BILTIR Center Forging Research and Application Laboratory. It has been observed that the numerical and the experimental results are in good agreement and a successful forging process design has been achieved. For the initial die temperature of 200 degree Celsius, to avoid the plastic deformation of the dies and the incipient melting of the workpiece, 350 degree Celsius is determined to be the appropriate initial billet temperature for the forging of the particular part.
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Deshpande, Mayur Nandkumar. "IMPROVEMENTS IN HOT FORGING PROCESS - USING ALTERNATIVE DIE MATERIALS AND FINITE ELEMENT ANALYSIS FOR WEAR PREDICTION AND DIE DESIGN OPTIMIZATION." The Ohio State University, 2010. http://rave.ohiolink.edu/etdc/view?acc_num=osu1293467038.
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Drbal, Jindřich. "Využití CAM softwaru PowerMILL 2018 při obrábění formy." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2018. http://www.nusl.cz/ntk/nusl-378868.
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The subject of submitted diploma thesis is complete structure of procedures necessary for the designing and subsequent production of forging dies for production of semi-finished connecting rods. The initial part deals with the design of forging die. Following part is consisted of materials used for production of this type of tools. Ensuing is proposal of tooling for machining of the die following with simulation of the milling processes.
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Mawissi, Kwamivi. "Modèles de représentation et de définition d'outillages de forme complexe : application à le génération automatique de processus d'usinage." Cachan, Ecole normale supérieure, 1995. http://www.theses.fr/1995DENS0001.
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Ce mémoire porte sur l'automatisation de la fonction de préparation a la fabrication permettant de passer de la conception des pièces brutes forgées à la définition et la fabrication des outillages. Notre apport se traduit principalement par la construction d'un modèle de représentation d'outillages qui établit le lien entre les différentes fonctions de production, et l'élaboration d'une méthode originale de génération du processus d'usinage des outillages. Nous proposons un modèle de representation d'outillages, permettant la conceptualisation des données de définition d'ordre géométrique et technologique suivant les aspects sémantiques, structurels et topologiques. Du point de vue des deux premiers aspects, la conceptualisation des données nous a permis de définir quatre éléments génériques (entité complexe, macro-entité, primitive et méta-primitive) qui servent de base a la représentation d'outillages. De plus, nous proposons une description formelle des interférences géométriques entre les éléments permettant de représenter à la fois les topologies locales et globales. Notre méthode de génération du processus d'usinage des outillages est basée sur la notion d'état d'usinage qui s'appuie à la fois sur les informations définies dans le modèle de représentation d'outillages et sur des connaissances d'usinage traduisant le savoir-faire des outilleurs. A cet effet, nous présentons une formalisation pertinente des connaissances d'usinage a partir de laquelle sont construits les états. Pour cette construction, nous avons adopte une démarche semi-ascendante de génération d'états d'usinage. La spécification de ces états, ainsi que la définition et l'ordonnancement des séquences d'usinage correspondantes conduisent à l'élaboration d'une gamme d'usinage des outillages. Enfin, nous validons notre approche sur un exemple industriel. La maquette informatique développée permet d'implémenter les taches de génération de gamme et d'unifier l'ensemble des données de représentation d'outillages dans un modèle objet homogène pour une exploitation pertinente et cohérente des liens existant entre ces données
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Farias, Marcelo Fernandes. "Determinação da influência de parâmetros de processo de forjamento a quente utilizando DOE (projeto de experimentos)." reponame:Biblioteca Digital de Teses e Dissertações da UFRGS, 2017. http://hdl.handle.net/10183/170979.
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Atualmente o Projeto de Experimentos (DOE) vem sendo largamente utilizado para determinar os fatores de projetos e processos mais significativos afetando uma variável resposta e para estabelecer modelos empíricos entre os fatores, entretanto este método ainda é pouco utilizado e processo de forjamento a quente. O presente trabalho analisa a influência individual e cumulativa de alguns parâmetros controláveis de um processo de forjamento a quente em matriz fechada na força de prensagem necessária para sua realização. Esta análise foi realizada utilizando a técnica de Projeto de Experimentos (DOE). Para a determinação da influência dos parâmetros de processo selecionados na variável resposta do Projeto de Experimentos (DOE), uma série de ensaios variando o lubrificante utilizado, o diâmetro da geratriz e a temperatura de forjamento foram realizados. A variável resposta para o experimento foi definida como a força de prensagem exigida do equipamento para a realização do forjamento. Para este trabalho foi utilizado o material ABNT 4140 fornecido em barras trefiladas de 28,6mm (1.1/8″) posteriormente forjado a quente em matriz fechada. Os resultados mostraram que o fator que mais influencia na força de prensagem para a situação ensaiada é o lubrificante. Os demais fatores, mesmo combinados, não apresentaram uma influência significativa na variável resposta. O presente estudo demonstra que é possível a utilização de técnicas de ajuste e definição de parâmetros de processo de forjamento a quente de maneira confiável e sem a necesside da aplicação dos complexos programas de simulação computacional e os métodos de tentativa e erro ainda presentes na indústria. Finalmente este trabalho reforça a versatilidade do Projeto de Experimentos (DOE) ainda pouco aplicado em processos de forjamento.Nowadays the Design of Experiments (DOE) has been widely used to determine the most significant project and process factors affecting a response variable and to establish empirical models among the factors, although this method is still little used and the process of hot forging. This work analyzes the individual and cumulative influence of some controllable parameters in a closed die hot forging process in the pressing force required for its realization. This analysis was performed using a Design of Experiments (DOE) method. To determine the influence of variable factors selected in response Design of Experiments (DOE), a several tests varying the lubricant, the diameter of the billet and the forging temperature was performed. The response variable for the experiment was defined as pressing force. For this study, it was used the ABNT 4140 steel provided in drawn bars of 28,6mm (1 1/8 ″). The fator that had more influence over the pressing force was the lubricant. Other factors, whether or not combined, did not show a significant influence on the response variable. This study demonstrates that it is possible use techniques to set hot forging process parameters reliably and without necesside the application of complex computer simulation programs or the trial and error system. Finally, this work reinforces the versatility of Design of Experiments (DOE) wich is still little used in forging processes.
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Halouani, Ali. "Modélisation et optimisation des préformes du procédé de forgeage par Approche Pseudo Inverse." Thesis, Reims, 2013. http://www.theses.fr/2013REIMS051.
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Une nouvelle approche appelée “Approche Pseudo Inverse” (API) est développée pour la modélisation du procédé de forgeage à froid des pièces axisymétriques. L'API est basée sur la connaissance de la forme de la pièce finale. Certaines configurations intermédiaires « réalistes » ont été introduites dans l'API pour considérer le chemin de déformations. Elles sont créées géométriquement sans traitement de contact et ensuite corrigées par la méthode de surface libre afin de respecter l'équilibre, les conditions aux limites et la condition d'incompressibilité. Un nouvel algorithme direct de plasticité est développé, conduisant à une méthode d'intégration plastique très rapide, précise et robuste même dans le cas de très grands incréments de déformations. Un modèle d'endommagement en déformation, est couplé à la plasticité et implémenté dans l'API. Les validations numériques montrent que l'API donne des résultats très proches des résultats de l'approche incrémentale mais en utilisant beaucoup moins de temps de calcul.L'API est adoptée comme solveur du forgeage pour la conception et l'optimisation des préformes du forgeage multi-passes. La rapidité et la robustesse de l'API rendent la procédure d'optimisation très performante. Une nouvelle technique est développée pour générer automatiquement le contour initial d'un outil de préforme pour la procédure d'optimisation. Les variables de conception sont les positions verticales des points de contrôle des courbes B-spline définissant les formes des outils de préforme. Notre optimisation multi-objectif consiste à minimiser la variation de la déformation plastique équivalente dans la pièce finale et la force du poinçon au cours du forgeage. Un algorithme génétique et un algorithme de recuit simulé sont utilisés pour trouver les points d'optimum de Pareto. Pour réduire le nombre de simulations de forgeage, un méta-modèle de substitution basé sur la méthode de krigeage est adopté pour établir une surface de réponse approximative. Les résultats obtenus par l'API en utilisant les outils de préforme optimaux issues de l'optimisation sont comparés à ceux obtenus par les approches incrémentales classiques pour montrer l'efficacité et les limites de l'API. La procédure d'optimisation combinée avec l'API peut être un outil numérique rapide et performant pour la conception et l'optimisation des outillages de préformeA new method called “Pseudo Inverse Approach” (PIA) is developed for the axi-symmetrical cold forging modelling. The PIA is based on the knowledge of the final part shape. Some « realistic » intermediate configurations are introduced in the PIA to consider the deformation path. They are created geometrically without contact treatment, and then corrected by using a free surface method in order to satisfy the equilibrium, the boundary conditions and the metal incompressibility. A new direct algorithm of plasticity is proposed, leading to a very fast, accurate and robust plastic integration method even in the case of very large strain increments. An isotropic damage model in deformation is coupled with the plasticity and implemented in the PIA. Numerical tests have shown that the Pseudo Inverse Approach gives very close results to those obtained by the incremental approach, but using much less calculation time.The PIA is adopted as forging solver for the design and optimization of preform tools in the multi-stage forging process. The rapidity and robustness of the PIA make the optimization procedure very powerful. A new method is developed to automatically generate the initial preform tool shape for the optimization procedure. The design variables are the vertical positions of the control points of B-spline curves describing the preform tool shape. Our multi-objective optimization is to minimize the equivalent plastic strain in the final part and the punch force during the forging process. The Genetic algorithm and Simulated Annealing algorithm are used to find optimal Pareto points. To reduce the number of forging simulations, a surrogate meta-model based on the kriging method is adopted to build an approximate response surface. The results obtained by the PIA using the optimal preform tools issued from the optimization procedure are compared to those obtained by using the classical incremental approaches to show the effectiveness and limitations of the PIA. The optimization procedure combined with the PIA can be a rapid and powerful tool for the design and optimization of the preform tools
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Mathew, Jerri, and 馬傑瑞. "Case based reasoning for Fastener Forging Process Design." Thesis, 2008. http://ndltd.ncl.edu.tw/handle/43233699442248416308.
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碩士國立高雄應用科技大學
工業工程與管理系碩士班
96
Engineers have always been on the run to design, develop and arrive at new solutions to problems in the quickest time possible. The increasing use Artificial intelligence (AI) has been an answer to this problem. This research uses Case based Reasoning (CBR) an Artificial Intelligence (AI) technology to arrive at solutions to problems encountered in real time situations at a rather quicker rate in comparison to the conventional methods. CBR uses explicit historical experiences to solve new problems. It assumes that problems reoccur and that similar problems have similar solutions. The work aims at reducing the trial and error processes required to arrive at the solution which otherwise would consume a lot of time. The research focuses on creating a Fastener forging process design system. Real time forging process simulations are created using the DEFORM tool and the results obtained are input into Protégé, a knowledge based framework that helps in constructing the system. Inputs includes realistic process sequences, taking into account the manufacturing conditions such as the number of forging loads, materials used., die and work piece dimensions etc. Various solved cases are input into the system to make the database. Frame based representation is used to represent the cases for the data base. Efficient case retrieval is achieved by a feature based similarity analysis. The work mainly focuses on the similarity measures(SM) required to arrive at retrieving solutions close to the problems encountered. SM represents a heuristic for estimating the a-priori unknown utility of the case. By describing the current problem, cases are retrieved based on global SM having the Attribute weights and local SM assigned to it. The efficiency and the competence of the CBR system is improved significantly by encoding more specific domain knowledge about the utility of the cases into the SM.
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Tsai, C. Y., and 蔡秋雲. "Investigation on the process design of a chisel hot forging." Thesis, 2015. http://ndltd.ncl.edu.tw/handle/43256172188304046250.
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碩士南開科技大學
車輛與機電產業研究所
103
A pneumatic chisel is often subjected a large shock wave, so that its mechanical properties need a higher strength and a higher toughness. However, in order to obtain the higher strength and the higher toughness of the part and to save the volume of the part material, a hot forging process is adopted most. In this paper, the hot forging design, the forging stage design, the die design and the flash trimming die design of a chisel forging are investigated. In this study, a commercial software DEFORM 3D based on the finite element method has been adopted for simulating and analyzing the material flow and the die stress, then the designed forging procedure could be evaluated efficiently during a design stage. The material SNCM439 is chosen for obtaining the needed strength and toughness after forging and heat treatment. An calculating excel program connected with SolidWorks software is set-up for drawing the die body automatically and saving the working time cost. From this study, a suitable hot forging die set of the chisel forging is developed. The results of this study could be a useful reference for a hot forging process design engineer.
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Liou, Jyun-Ding, and 劉俊玎. "Forging Process and Die Design for Ring Productswith Internal Gear Features." Thesis, 2014. http://ndltd.ncl.edu.tw/handle/v5c2ed.
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碩士國立高雄應用科技大學
模具工程系碩士班
102
Ring products with internal gear and central boss are made by cold forging process to increase the mechanical properties. The roots of the internal gear and the central boss on the web are difficult to cut. Usually, hot forging process is adopted to make the gear blank and the following machining process is required. It takes more using this conventional manufacturing way. The objective of this research is to develop a new precision forging die design method to solve close-end internal gear unable manufacturing problem, increase the mechanical property, and reduce the forging loads. The forging ring product without gear features was studied for understanding of material flow characteristic using hollow and solid billets, respectively. A hollow billet was adopted to make this part without internal gear features using one step backward extrusion. A solid billet was adopted to make the part with internal gear features using multi-pass forging process. The one-step forging process required higher forging load as expected than the multi-pass design. Base on the forging characteristic information of the simplified product model without gear features, modified processes parameters were adopted to the one-step and the multi-pass forging of full product model with gear features. The one-step forging process not only had the problem of high forming load but also showed the occurrence of under filling due to the unbalanced material flow between the boss and the gear features. A new preform design method using two Bezier curves with G1 continuity was proposed. Taguchi method was adopted to find the optimum adjustment of the control points of the Bezier curves. The optimized preform design using the proposed method was able to control the material flow of the finish forging and obtain sound product.
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KAN, PING-CHENG, and 甘秉正. "The Study of Hot Forging Die Design and Process Development for Slider." Thesis, 2018. http://ndltd.ncl.edu.tw/handle/35j4pg.
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碩士國立高雄第一科技大學
機械與自動化工程系碩士班
106
This study is to research the slider conducted which is generally made by foundry. Because of the common foundry easily causes the defects like voids and fissure. So in this experiment, hot forging process is used for the material refinement, homogenization and better fatigue resistance, toughness, etc. The material in this study is the general round bars and the hierarchy round bars to compare the compatibility and the formability of each other in different processes. Before the particle development, use the Deform-3D for simulation for data like the forging loads or stress of die set to evaluate the possibility of the whole process. As result, in temperature 1050℃,the forming load of the general round bars falls in between 330 tons to 370 tons which is close to the outcome of simulation 339 tons, but the mold cavity haven’t been completely filled up. On the other hand the hierarchy round bars at the same temperature not only the forming load which is around 340 tons to 380 tons matches the modeling data 360 tons but also expressing better formability, which means the hierarchy round bars are more suitable for the slider manufacturing. After the mold trail, the major dimensions of object are in compliance with the requirements and it’s stable. Forming die stripping will be improved and mass production. According to the forming and the stability of dimensions, this mold design works efficiently with great precision. Keywords : Slider, Hot forging
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CHIANG, CHIA-WEI, and 江嘉偉. "The Study of Hot Forging Die Design and Process Development for Eye Bolt." Thesis, 2017. http://ndltd.ncl.edu.tw/handle/a9pmgv.
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碩士國立高雄第一科技大學
機械與自動化工程系先進製造科技碩士班
105
This study is to research stainless steel eye bolts. The eye bolts are currently produced in the traditional hot forging process, because the billet volume distribution is different. The process design generally needs to be preformed by extruding or upsetting. The extruding preforming process needs a large forming load and uses more materials. About the upsetting preforming process, if the material's ratio of length vs diameter is too large, it needs to forge several times to head forming, Therefore, we develop the eye bolt hot multi-station forging process. In the preforming, the design of the extruding preforming and binding upsetting preforming to proceed this process's development and actual test. This study is planning to use diameter Ф25mm and Ф11mm bar material, by different preforming method is divided into two kinds of process, the Ф25mm bar manufacturing process is extruding preforming process, which is including extruding preforming, flattening, burrs to complete forging, punching and trimming; Ф11mm bar manufacturing process is binding upsetting preforming process, which is including binding upsetting preforming,burrs to complete forging, punching and trimming. By using the metal forming simulation software DEFORM-3D to simulate for hot forging. Then to explore two processes are based on same parameters, the difference between in hot forging the forming load and the die stress and the process design when the material is under the same parameters. According to the simulation results, the physical mold development and actual test, to establish a better process parameters and data. The results show that the two manufacturing processes of this study are carried out by the actual hot forging, and the forming situation is in accordance with the simulation. Billet is completely formed, the surface is without defects. The burrs thickness is designed for 2 mm in completed forging, the extruding preforming process simulated forming load is 134ton, the forming load is 154ton. The binding upsetting preforming process simulated load is 92.9ton and the forming load is 94ton.In contrast, the binding upsetting preforming process can save about 7% of the material. In upsetting by the mold design, the material's ratio of length vs diameter by the 5.45: 1 can be formed once, So the less number of stations can reduce manufacturing time, increase material usage and reduce costs. This study shows that the binding upsetting preforming process is a preferred forging process for the eye bolts.
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Shih, Ting-Yu, and 施亭妤. "Design and Analysis of Forging Process for the Rear Leg of Aircraft Seat." Thesis, 2016. http://ndltd.ncl.edu.tw/handle/4358c3.
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碩士國立虎尾科技大學
機械與電腦輔助工程系碩士班
104
As the aircraft passenger seat develops for safety and lightweight, in order to maintain reasonable production cost, its structure of process design is increasingly important. The rear leg, which sustains the maximum load-carrying capability, is one of the key components. In response to the high strength and light weight of structural design, it could hardly forged to the desired size and must to match the high cost of machining to achieve finally product size on the ordinary forging technique. To reduce the manufacturing process and cost, this study attempts to forge directly with seat parts production of meet the size by isothermal forging. The FEM analysis software DEFORM-3D was applied to discuss the formation of the H-type cross section of rear leg of aircraft passenger seat. Various manufacturing variables were designed for testing by using laboratory scale model. By comparing the result of simulation and experimentation, it proved the feasibility of applying such technique on rear leg of passenger seat. Results showed the application of Deform-3D to simulate the forging of rear leg of passenger seat could effectively display the entire process. And, the effective stress for the forged piece of rear leg was primarily distributed the web plate, the effective strain was primarily distributed around the fillet corner of web plate, and the peak die load could reach 1650 tons. In the analysis on non-isothermal forming, increase die and blank temperature could reduce the forging forming load and stress and strain. The control of temperature for the blank molding was an important parameter for affecting the loading. From the experimentation and analysis comparison, the forged pieced of contour matched. In size comparison, the forged piece minimum deformation of end was 0.21%, the maximum deformation of web was 56.44%. By the results of the analysis can prove the reliability of using analysis software for this procedure, and further illustrate the application of the finite element software for feasibility of isothermal forging process of rear leg. And, it helped to understand the material dynamics, effective stress, effective strain, forming force and forging flow line in the process and its prediction and control of contour.
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Pai, C. M., and 白佳敏. "Study on the Hot Forging Process Design of a VDI Static Tool Holder." Thesis, 2015. http://ndltd.ncl.edu.tw/handle/61489064068950116242.
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碩士南開科技大學
車輛與機電產業研究所
103
A VDI static tool holder is suitable for high speed tool machine because of its high strength and high toughness. However, in order to obtain the strength and the toughness of the part and to save the volume of the part material, a hot forging method is adopted most. In this paper, the economy cost analysis for different forging models, the hot forging design, the forging stage design, the die design, the flash trimming die design and the die stress analysis by the FEM are conducted. From this study, a suitable hot forging die set of a VDI static tool holder is obtained. The results in this paper are listed as follows：(1) an economy cost analysis sheet of forging models is established for obtaining a better economic forging model; (2) the maximum effective stress of the die is lower as choosing a taper expanding die.
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Chang, Shu-Hua, and 張書樺. "Multi-Axes Forging Die and Process Design for an Aluminium Alloy Stem of Bike." Thesis, 2008. http://ndltd.ncl.edu.tw/handle/78825391119817095086.
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碩士國立高雄應用科技大學
模具工程系碩士班
96
The configuration and functionality of bike are varied in a complex way. As a result, the geometry design of bike components is more and more complex. The conventional forging press with one-direction of action is not able to forge and eject smoothly due to the interference of complicated part geometry with the die cavity. A 3D press with multi-direction of action is able to forge and eject the forming parts with no occurrence of die interference. The production integration and process flow of a 3D press are improved owing to the flexibility of multi-axel movement. In this thesis, design methods of the die geometry, die bearing, and forging process are proposed. FEM simulations were carried out to analyze the forming process; two hollow products of bike were forged using the developed design methodology. A special die configuration design of one cavity coping with two punches was proposed to produce similar product with different dimension of axial length in the same die. The end bar and the stem of bike were adopted to demonstrate the one-step and two-step forging process design. The stem product is not able to be ejected after forging in a one-direction forming press. The one-step and two-step forging processes were designed for a multi-direction 3D forging press. The complicated punch designs were proposed to produce a single specification product in the one-step forging process. The preform and punch designs were proposed to produce multi-specification products in the two-step forging process with a die configuration of one-cavity and two-punch. The multi-step design is not only able to lower the forging and clamping loads but also avoid the folding defects.
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Su, Yi-Chung, and 蘇義忠. "Process simulation and die design for aluminum alloy hot forging of a bike component." Thesis, 2010. http://ndltd.ncl.edu.tw/handle/60189551178495075857.
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碩士國立高雄應用科技大學
模具工程系
98
This study aims at the simulation of the inter-heating forging process of aluminum alloy A6061 for the design of the forging mold (or die) used in the motorbikes, and the commerce software, DEFORM, with finite element method DEFORM is the most extensively utilized (introduction) in current dynamic analysis. Compressing the round rod made of aluminum alloy A6061 with ∮36mm x 115mm by various impulse velocity into the depth of 16mm in 3.0, 1.5, or 0.75 seconds, respectively. This study uses these simulations of forging forming to find the optimal velocity for A6061 concerning the temperature variation and forming effect in material. This study experienced a support rack (or prop stand) of motorcycle front running-board. This experimented part has been mass produced by a good reputation company. This forging process refers to the design and the performing, which is a traditional method to make the aluminum alloy forging mold. and consider the mold needs a continuous testing and modification. Also, In order to prove the software DEFORM of finite element method forges the feasibility analyzed in simulation of the inter-heating forging process of aluminum alloy A6061. Using forging forming analysis designs the coarse mold for the forging and the precision mold for the finish parts. To detect the insufficient filling and the stacking issues frequently encountered during the hard forging process by using DEROM to analyze forging and forming processes. Using the DEFORM software could shorten the developing time of a forging mold from four weeks to two to three weeks. Consider the forming effects from different profiles and locations of coarse mold by forging simulation and analysis to find out the optimal forging process. This study had verified not only the feasibility of the finite element analysis software but also revised the design of the forging mold from this practical product.
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Vu, Dinh-Du, and 武廷譽. "Design and Optimization of Closed-Die Hot Forging with Flash Process using Taguchi Method." Thesis, 2015. http://ndltd.ncl.edu.tw/handle/87163520606573926122.
Full textAbstract:
碩士國立高雄應用科技大學
製造與管理外國學生碩士專班
104
One of the most adopted methods for forming complex shaped parts with satisfactory geometrical accuracy is closed die hot forging process. The main reasons forgings are so important is the strength and reliability inherent in their manufacturing process. Hot forging technology has a special place in producing parts of superior mechanical properties with minimum waste of material. In manufacturing process, the optimization of product conditions is required to apply for decrease forming load and production time. Therefore, the effect of the most important process parameters has to be investigated. Finite element method was applied in this research to analysis closed die hot forging process. The most impact process parameters are flash thickness, billet temperature and friction coefficient parameters had been chose to do research with purpose to reduce forging load using Taguchi method. The most significant parameter affecting the responses is billet temperature using analysis of variance (ANOVA).
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Ye, Sung-Jang, and 葉松彰. "Computer-Aided Design for Developing the Cold Forging Process of Steering Yoke of Automobiles." Thesis, 2015. http://ndltd.ncl.edu.tw/handle/83956668494795612521.
Full textAbstract:
碩士國立高雄第一科技大學
機械與自動化工程研究所
103
Steering yoke as an important part of automotive driveline components, is one of the important parts for transmission the power, there has the safety requirements. Otherwise the danger may occur .Now a days warm forging is the most common process for Steering yoke. Products of warm forging will produce many flash. Machining is needed. Therefore, this study using Steering yoke for Carrier, planning to develop the bar material cold forging , Establish Relevant process parametersand mold design. Using the drawing software SolidWorks 3D to establish the model. Then simulate the cold forging by Metal Forming simulation Software DEFORM-3D ,discuss the Formability, possibility and process of forming load by this materials ,finally Mold development and practical test are base on the simulate results, test out the better process parameters, to reach the goal of the reduce material used and process time when manufacturing . Due to the simulate result by DEFORM-3D, The flow of the billet and the mold stress is with reason,the surface has no crash and material fold , and cold forging`s billet are less material used for 18816.764mm3 compare with warm forging, Saving material about 39%. In the forging experiment, the real cold forging of the steering yoke`s realistic formed load are really close of the simulate software DEFORM-3D.the forming load has about 20 ~ 40 tons simulation deviate . From the non-centering process. Two side legs spots feature are not has the same height and two side Fillet feature has over heat and char by Simple lubricate were be found. and the process with centering process and well lubricate, Two sides of the legs feature are almost same height and two sides of the fillet feature are complete and no longer over heat and char were be found. Therefore, the forging process of the study combine cold forging with centering process and the dual lubricate by saponification and lubricants for the ideal process conditions.
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Chen, Ching-Chiun, and 陳清圳. "Studies on Intergrated System for Process Design and Analysis of Three-Dimensional Hot Forging." Thesis, 1993. http://ndltd.ncl.edu.tw/handle/33163658710553139161.
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碩士國立成功大學
機械工程研究所
81
In this thesis, an integrated system for process design and analysis of hot forging is proposed. The system is feature- based for rib-web typed three-dimensional hot forged parts. The system is integrated into a structure of computer software which combines the experience-based design guidelines, and the science- based analysis and simulation. By using the proposed system, the user needs only to input the product data, then the system can determine the geometry of the forged part, the blocker part, and the forging die automatically. The system also can transfer the result into a CAD/CAM package for the simulation of NC-tool path and for the manufacturing of forging die. First, the domain knowledge of hot forging is described systematically, including the construction of hot forging process model and product model, and the relations among them. Based on these relations, a geometry design oriented knowledge- based system has been implemented for three-dimensional multistage hot forging process and die design . The experience rules are difficult to be accumulated, so in this study a preform design rule generated from the reverse forming using upper bound elemental technique is proposed to aid the lack of the experience rules of the system. This study also uses upper bound elemental technique for the prediction of forging load and metal flow so that the preliminary design can be evaluated with confidence. Finally, a rib-web typed three-dimensional hot forging example, including the design of forged part, the finisher die, the blocker part and the blocker die, the process analysis, the simulation of NC-tool path, and the machining of electrical discharge electrode, is given to demonstrate the capability of the developed system.
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Yang, Sang-Jung, and 楊尚融. "A Study of Forging Process and Die Design on a Heat Sink of Straight Fin." Thesis, 2002. http://ndltd.ncl.edu.tw/handle/69624553028667839307.
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碩士國立高雄第一科技大學
機械與自動化工程所
90
Recently, the speed of the computer processor is getting faster and faster, which is followed by generation of a great deal of heat. How to eliminate the heat fast and effectively by using the heat conductive media is a topic worth to research. The efficiency of the heat sink depends on material properties and the effective heat surface area for conduction. Forging is the only process to increase the surface area of a heat sink to promote the efficiency of heat conductivity. In this study, the forward extrusion process variables of a heat sink of aluminum are investigated. First the CAE software, “DEFORM-3D”, is used to analyze the forward extrusion process and the variables in extrusion die design are investigated. Then, the optimum variables according to the results of CAE simulation are used to design the actual die and are certified by the forging experiment using A6061 aluminum alloy as the billet. The results show that the forging loads are proportional to radii of die. When the land is 5mm, the fins of heat sink are the straightest. The load of 22 tons is the lowest and the fins are straightest when the radius is 0.5mm and the land is 5mm, which are the optimum variable in the CAE simulation. Then the optimum conditions are used to design the extrusion dies and proceed with the forging experiment. Not only the forging load but also the stress distribution and product appearance in the actual forging conform to those in the DEFORM simulation. Therefore, it is feasible that using the DEFORM software simulates the forging process to find the optimum variables previously and then the design of the forging die is proceeded according to the optimum variables.
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Shu, H. F., and 徐華鋒. "Investigation on the process design of the near net shape hot forging of a tool holder." Thesis, 2015. http://ndltd.ncl.edu.tw/handle/34641285715469829116.
Full textAbstract:
碩士南開科技大學
車輛與機電產業研究所
103
A static tool holder is suitable for high speed tool machine because of its high strength and high toughness. However, in order to obtain the strength and the toughness of the part and to save the volume of the part material, a hot forging method is adopted most. In traditional tool holder forging, a forging with a radial flash will be found. The flash is harmful to the machining work and the tool life of the forging cutting. Under the international competition market, Automatic CNC machine center should be adopted necessarily for the sequential machining work after forging. A net or near net shape forging is needed for a smooth going of the automatic grip, location and cutting. In this paper, the process design of a near net shape hot forging of a tool holder is studied, including the forging design, the forging stage design, the process simulation and the forging die design. The forging history and load, the influence of the different types of radial flash and axial flash forging on the die stress and material usage percent are also investigated. From this study, a suitable near net shape hot forging die set of a tool holder is obtained. The results in this paper are listed as follows： a higher technology in the die manufacture and the forging die setup is needed; a higher forging load and a higher die stress will be found in a near net shape hot forging comparing a traditional forging. Finally, a qualified forging is obtained and the forging is advantageous for an automatic CNC machine work.
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Lin, Chun-de, and 林俊德. "A study on the precision forging process and die design for aerospace fastenings of nickel base superalloy." Thesis, 2013. http://ndltd.ncl.edu.tw/handle/cg6k79.
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C, Hsieh C., and 謝君政. "The Analysis of the Critical Value for the Mold Design Parameters of the Forward Extrusion Cold Forging Process." Thesis, 2013. http://ndltd.ncl.edu.tw/handle/29856502101638165470.
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碩士建國科技大學
機械工程系暨製造科技研究所
101
The process of cold forging process is widely used in the industry. The process is fast and has high-precision and high strength. Cold forging process depends critically on the mold design. So how to predict the forming results of the workpieces correctly is the key point of die design of the cold forging process. Forward extrusion process is one of the classical cold forging processes. Whether the workpiece will rupture or overflow in the process is mainly depend on the tapered angle and the section reducing rate. The purpose of this study is to construct the criterion for mold design parameters of the forward extrusion process. We use Solidworks CAD software to generate the figures of molds and workpieces. The material of workpieces is S45C carbon steel. And the material of mold is SKD11. We use “Simufact” forging software to simulate the forging frocesses. Three kinds of tapered angle and five kinds of section reducing rate are chosen to be simulated. The simulation results are exported. And then we use neural network to simulate these results. According to the trained neural network, we can construct a limit curve of parameters for the forward extrusion process. The limit curve of parameters for the forward extrusion process can be checked by some other kind of tapered angle and section reducing rate. The simulation results for those parameters by “Simufact” is consistent with the limit curve. Keywords: cold forging, forward extrusion, artificial neural network.
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Huang, Jie-Hong, and 黃傑泓. "Numerical analysis and experimental validation on multi- stage warm forging process of deep groove ball bearing --- defect analysis and tooling design rationalizationNumerical analysis and experimental validation on multi- stage warm forging process of deep groove ball bearing --- defect analysis and tooling design rationalization." Thesis, 2016. http://ndltd.ncl.edu.tw/handle/95338p.
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碩士國立中央大學
機械工程學系
104
In this study, a multi-stage warm forging process for making bearing rings is numerically and experimentally investigated. The aim of the study is to determine the crucial station of the finishing forging process such that the tool wear is prolonged and tool fracture should be minimized. In addition, in order to ensure the appropriateness of the suggested modification, a 3-dimensional finite element simulation on each sequence is performed, and carefully compared with experimental investigations. Numerical simulations results indicate that the redesigned upper punch geometry, radius(R2) of the finishing forging process, demonstrates drastically different deformation rate (the effective strain/effective stress distribution) and material flow pattern, as compared with chamfer (C2) counterpart. Accuracy of the numerical models has been verified by comparing with experimental measurements . In addition, the numerically and experimentally validated process includes the detailed tooling design and dimension variation, which is of great importance in maintaining the overall structural integrity of the forging die/punch and thus, the stability of the whole process. Concerning on the waste ratio comparison, the method used steel rods are as raw material and the IR/OR rings form is given by hot/warm forging and sequential cold rolling processes and the waste ratio decreases to ~9%. Finally, it is shown that the multi-stage warm forging process in this study could be successfully applied to the high-quantity production (10,000 pieces/hr) of the IR/OR of the deep groove ball bearing with the stability and structural integrality of the whole process.
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Chen, Iu-Ren, and 陳裕仁. "A Study of Design of Mechanism fo a Vertical Multi-action Die Set and Analysis of its of Forging Process." Thesis, 2002. http://ndltd.ncl.edu.tw/handle/95175906111853616985.
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碩士國立高雄第一科技大學
機械與自動化工程所
90
Abstract The multi-action forging process is one of the developing directions of forging technology. In this study, the mechanism design of multi-action on the forging die set will be discussed. At first, using simulation software “DEFORM” is used to analyze the stress, strain and material flow of the billet. The optimum conditions of the multi-action forging process will be investigated and established by the simulation results. According to the optimum conditions, the multi-action mechanism will be tried by a screw set. Finally, the feasibility of multi-action die set design is investigated by forging the spider with plasticine. According to the results of DEFORM simulation , the conventional forging process needs the highest load and the material flow in the single direction of multi-action forging process is non-uniform. When the velocity ratio of the upper punch relative that of to die in double directions of multi action forging process is two to one the material flow is uniform with no defect and the lowest load, that is the optimum condition. According to the condition, the design variables of the multi-action forging die set are as follow: The diameter of upper screw bar is 30mm and the angle fo upper screw is 60°. The outer diameter is 60mm ,inner diameter is 30mm for the lower screw tube and its screw angle is 23.4°.Then, the forging experiment with plasticine are proceeded and the shows that the results is confirm with the DEFORM simulation data. Therefore, it is practicable to control the relative velocity between the upper punch and die by using screw set design for multi-action forging process to obtain the expected forming condition. keyword：multi-action , screw , plastic
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Che-WeiChang and 張哲維. "Construction of Knowledge-Expandable Ontology-Based Expert System—Cold Forging Process and Tool Design of Flange Nuts as an Example." Thesis, 2016. http://ndltd.ncl.edu.tw/handle/6nf65a.
Full textAbstract:
碩士國立成功大學
機械工程學系
104
This study proposes a method of constructing an ontology-based expert system with an expandable knowledge base. The cold forging process and tool design of flange nuts is taken as an example to demonstrate the method. There are two essential parts of this method. In the first part, the software Protégé is used to express experiential knowledge as a Web Ontology Language (OWL) ontology and Semantic Web Rule Language (SWRL) rules. The inference is executed in Java by means of the API provided by Jess, the rule engine for the Java platform. In the second part, new knowledge is acquired from parameter optimization experiments, combing process simulation and Taguchi methods. The new knowledge is represented as an OWL ontology and SWRL rules, expanding the knowledge base of the system. The knowledge base can thus be expanded if there are any modifications or new knowledge in the future. The system is capable of inferring a workable forging process and recommended dimensions of tools after the necessary information, such as the nominal size and specifications of the product, has been input. Users are able to reduce tool design time by taking the results from the system as a decision support.
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Lin, Long-Chi, and 林龍基. "The development of precision forging process for the receiver of rifle andthe study on design and manufacturing of its precision die." Thesis, 2004. http://ndltd.ncl.edu.tw/handle/00583644225355995576.
Full textAbstract:
碩士國立高雄第一科技大學
機械與自動化工程所
92
The receiver is one of the important parts in a rifle, in which the bolt carrier assembly moves. This part is also the adaptor for connecting the barrel. If the quality of the receiver is not well, the movement of the bolt carrier assembly will be affected and the failing of shooting will be resulted in, even the bolt carrier assembly stick. In this situation, the explosion will occur and the safety of operators will be threatened. This receiver is forged by using 7075 aluminum alloy as the material. Therefore, its quality will be assured through precision forging process by the well design in the precision forging die and the strict control in the process variables. Then, the quality and the safety of a rifle will be assured during the further machining due to the reducing in the machining amount and the maintaining in dimension accuracy. In this project, the CAE simulation technology combining with precision die design technology and aluminum precision forging process technology is used to develop the precision receiver forgings in a rifle and the relative process information is expected to be built up. First of all, the CAD model of the receiver is built up and then the simulation during forging proceeds by using DEFORM software. The effects of forging die design variables on the result after forging are investigated. According to the optimum condition within the results of simulation, forging dies are designed and manufactured. Afterward, the dies are tested to develop the precision receiver forgings. The conditions for mass production are assured and are provided to the military as reference. Finally, the self-made mass production technology for the military article is expected to be established. The results show as follows： (1)It can reduce the cost of manufacturing die，shrinkage the time of testing and lower the possibility for the failure of die to simulate the design of die first by CAE technology and then to proceed the manufacturing of die according to the optimum results. This procedure show available in developing the forging die. (2)It can dramatic reduce the cost of cutting tools and the lead time for making the forging die by using high speed machining technology. (3)The surface qualities of the forging materials have much effect on the surface qualities of the forging parts. So, it is very important for the materials with no defects on its surface during forging.
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Yu, Cheng-Hsien, and 余征諴. "Designs and Simulations of the Different Height-to-Diameter Ratio Shaft Forging Process and the Tube Flanging process." Thesis, 2015. http://ndltd.ncl.edu.tw/handle/2qnc9d.
Full textAbstract:
博士國立高雄應用科技大學
模具工程系碩士班
103
Forging technology development is more and more complex due to the demanding of new high strength material and features of product geometry, such as the muti-action forging and the incremental forming. The difficult-to-forge technology developed in this research include the highly variation of length-to-diameter forging and the one-piece stud tube making. The pass and the preform designs were proposed to improve material flow and avoid forming defects. CAE analysis of forming and die stress is conducted and verified using experiment tests.The products of difficult-to-forge studied in this research are the long bulged bush (ratio of length to diameter is 3), the large flat disk forging (ratio of length to diameter is 0.16), and the stud end of tube (ratio of thickness to diameter is 1/38). The long bulged bush has small spike features at two ends and different thickness distribution. The bulged belly at middle and the small features at two ends result difficulty of die fillings. A backward extrusion preform design and a multi-axes finish forging with flash gutter design were proposed to solve the die filling problem. The disk part with the involute inner gear and the central hub features was difficult to fill the die cavity of small gears. The preform design with smaller offset inner gears and the lateral extrusion finish process were proposed. The lateral extrusion was able to control the material flow of die filling and reduce the forging load with the proposed preform design. The one-piece stud end with different thickness of flange and tube was manufactured using a roll-formed uniform thickness tube. The problems of thickness control and the formability were big issues to be solved. Four tube thickening preforms were designed in coping with the multi-axes preform forging and the orbital flanging forging. The necking and cracking defects of flanging were avoided and the thicker flange was obtained. The process and die design methods of the long bulged bush, the large flat disk forging, and the one-piece stud end of tube were proposed. The CAE simulations were carried to evaluate all designs. The experimental works were conducted to verify the feasible designs for different products. The results of the experiment tests were in good agreement with the CAE simulations. The proposed designs were all transfer to industrial productions to validate the feasibility of the research works.
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Cheng-Hsien, Yu, and 余征諴. "The Process Analysis and Die Design of the Conventional and the Orbital Press Forgings for Gear ProductsThe Process Analysis and Die Design of the Conventional and the Orbital Press Forgings for Gear Products." Thesis, 2006. http://ndltd.ncl.edu.tw/handle/56207510435499050019.
Full textAbstract:
碩士國立高雄應用科技大學
模具工程系碩士班
95
The aims of this paper are to establish the optimum die design methods of the conventional and the orbital press forgings systematically. The characteristics of conventional and orbital cold forging processes for gear parts were studied. The parameters of preform and die designs taken into consideration are fillet and corner radii, and the angle of draft; the considered orbital forging process parameters includes the punch inclined angle, locus of the punch rocking, and the rotational speed of punch with respect to the press vertical axis. The process and die design evaluation by computer simulations were established. In this study, the upsetting tests, ring compression tests, and 2D FEM simulations were carried out to establish the flow stress model of material, find the friction coefficients, and the calibration curves, respectively. The involute gear profiles and the 3D geometrical models were designed using the CATIA software. The preform and die designs were accomplished based on the 3D product model. The DEFORM3D was adopted to do the forming simulation and the die stress analysis, and the stress rings were designed to improve the die life. In this paper, many preform designs were proposed to avoid the folding defects of the conventional gear forging. Different 2D simulation methods were proposed to obtain a quick result and the comparisons showed a good agreement with the 3D simulation. The punch is very easy to be fractured under the torsional stress of orbital forging in the cases of hollow forging process. Many types of special punch profile and preform were designed to avoid the fracture problems, and the stress ring design copes with the suitable amount of interference was proposed to lower the die stress and prolong the die life. The prediction results were compared with the experimental works and a good agreement had been achieved. It demonstrates the proposed simulation and design methods are correct and feasible.