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 stu...

The performance of hot-forging dies, in which the die cavity is weld-deposited with a layer of modified H12 hot-work tool steel, has been studied, using a continuous monitoring of the die condition as well as macroscopic and microscopic examination. It was observed that the thickness of the hard upper ‘capping layer’ and that of an intermediate ‘buffer layer’ have a pronounced effect on the lif...

Abstract—Closed die forging is a very complex process, and measurement of actual forces for real material is difficult and time consuming. Hence, the modelling technique has taken the advantage of carrying out the experimentation with the proper model material which needs lesser forces and relatively low temperature. The results of experiments on the model material then may be correlated with t...

This paper presents an approach for a holistic simulation of forging processes considering the interactions between forging press, tooling system and forging process. It can be used in coupled simulations and will enable industrial users in forging industry to do simulation-aided tool optimizations in the design stage of newly developed forging dies. The final aim is to reduce the time-consumin...

Design of the optimum preform for near net shape manufacturing is a crucial step in upsetting process design. In this study, the same is arrived at using artificial neural networks (ANN) considering different unequal interfacial friction conditions between top and bottom die and billet interface. Back propagation neural networks are trained based on finite element analysis results considering f...

As an important problem in forging factories, dies are destroyed because of high wear rate, plastic deformation and thermal and mechanical fatigue at high temperatures. This paper is an investigation into        the use of nickel super alloy with different welding parameters. Three weld overlaid alloys of inconel625, as wear resistance hardfacing materials on H13 tool steel, with different weld...

Within the manufacturing process planning, blanks are either selected or designed, respectively forms of input material for the manufacture of products. Reviewed in this paper are three types of group blanks: group castings, group forgings manufactured by closed die forging and free forging, and group blanks manufactured by pressing melted metal in casts. The paper also presents requisites for ...

Radial forging is an open die forging process used for reducing the diameters of shafts, tubes, stepped shafts and axles and also for creating internal profiles such as rifling the gun barrels. The radial forging of tube is usually performed over a mandrel to create an internal profile and/or size the internal diameter. Most of the previous studies conducted on the radial forging process have u...

-A method of discretizing the die boundary conditions is considered for the analysis of metal forming processes by the rigid viscoplastic finite element method. The method is natural to the finite element method and general enough to treat the boundary conditions of arbitrarily shaped dies in a unified way. Solutions of the spike forging process are obtained by using the method. The deformation...

The results from experimental research of deformation by upsetting and die forging of lead specimens wit controlled impact are presented. Laboratory setup for conducting the investigations, which uses cold rocket engine operated with compressed air, is described. The results show that when using controlled impact is achieving greater plastic deformation and consumes less impact energy than at o...