DESIGN AND ANALYSIS OF FORGING DIE TOWARDS IMPROVING LIFE OF CLOSED DIE BY USING FINITE ELEMENT ANALYSIS

Mechanical Engineering

Forging process is one of the most adopted methods for forming complex shaped component with geometrical accuracy. More than fifty percent of the forgings are processed through this way. Forged components required in many engineering sectors, most of them in the automotive sector. The majority of the safety critical component and load bearing structural components are process through it. The benefit of forging is faster productions of complex shapes with less wastage of material. For the complex shape component, metal flow analysis of the process is very difficult because a number of experimental testing and production trials are being done in the industry in order to develop a strongly formed manufacturing process. Such practices involve huge investment in tools and raw materials as well as valuable time and efforts .To take the virtual trials and simulation based design finite element method is best suitabletool.This would lead to an improvement in overall efficiency of the process at a lower cost. As a sample case, a real life automotive driveline component like yoke, is taken for investigation. A simulation approach using a (SIMUFACT), based on finite element method. Trials were conducted using an industrial forging press machine a generated were validated against those predicted in simufact software. The relation between them was found to be similar and satisfactory.A typical yoke, used in the propeller shaft of heavy commercial vehicles may be considered as a sample component. The research involved analysing the initial effects of (1)friction, (2) workpiece temperature, (3) die temperature, and (4) Flash Thickness were examined. To obtain the results the forging process was design in PTC creo 3.0 , simulated in Simufact Software and experimental setup and examined using two-level full factorial design of experiments (Analyzed with Minitab &MS. Excel).Theproduct reviewed was at the VARSHA FORGING Waluj, Aurangabad.

This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.