Design and Simulation of Forging Die Towards Improving Life of Closed Die

Akshay S. Nandalgaonkar; Sachin C. Borse

Abstract

Forging is the metal forming process which is used for forming complex shaped component withgeometrical accuracy. More than fifty percent of the forgings are processed through this way. Forgedcomponents required in many engineering sectors, most of them in the automotive sector. Themajority of the safety critical component and load bearing structural components are process throughit. By using forging process production of complex component is faster with less material waste. It isvery difficult to do number of experimental testing and production trials are being done in theindustry in order to develop a strongly formed manufacturing process of complex component. Suchpractices involve huge investment in tools and raw materials as well as valuable time and efforts. Totake the virtual trials and simulation-based design finite element method is best suitable tool. At lowercost it would lead to improvement in life of die. As a sample case, a real-life automotive drivelinecomponent like yoke, is taken for investigation. Based on finite element analysis simulation is dine inSimufact. Different trials were done by using a forging press machine and validated against thosepredicted in Simufact software. The relation between them was found to be similar and satisfactory. Ayoke is used in the propeller shaft of heavy vehicles is considered as a sample component. Theresearch involves analyzing the initial effects of (1) workpiece temperature, (2) friction, (3) dietemperature, and (4) Flash Thickness were examined. To obtained the results the forging process wasdesign in PTC Creo 3.0, simulated in Simufact Software and experimental setup and examined usingtwo-level full factorial design of experiments (Analyzed with Minitab and MS. Excel). The productreviewed was at the Varsha Forging Waluj, Aurangabad.

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