Open Access
Akshay S. Nandalgaonkar
Sachin C. Borse
- Research Scholar Deogiri Institute of Engineering and Management Studies Aurangabad, Maharashtra India
- Assistant Professor Deogiri Institute of Engineering and Management Studies Aurangabad, Maharashtra India
Abstract
Forging is the metal forming process which is used 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. By using forging process production of complex component is faster with less material waste. It is very difficult to do number of experimental testing and production trials are being done in the industry in order to develop a strongly formed manufacturing process of complex component. 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 suitable tool. At lower cost it would lead to improvement in life of die. As a sample case, a real-life automotive driveline component like yoke, is taken for investigation. Based on finite element analysis simulation is dine in Simufact. Different trials were done by using a forging press machine and validated against those predicted in Simufact software. The relation between them was found to be similar and satisfactory. A yoke is used in the propeller shaft of heavy vehicles is considered as a sample component. The research involves analyzing the initial effects of (1) workpiece temperature, (2) friction, (3) die temperature, and (4) Flash Thickness were examined. To obtained 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 and MS. Excel). The product reviewed was at the Varsha Forging Waluj, Aurangabad.
Keywords: Die life improvement, Simufact, ANOVA, Taguchi, modeling
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Journal of VLSI Design Tools and Technology
| Volume | |
| Received | March 24, 2021 |
| Accepted | April 1, 2021 |
| Published | April 1, 2023 |