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u00a0Akshay S. Nandalgaonkar, Sachin C. Borse,
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nJanuary 9, 2023 at 6:43 am
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nAbstract
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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.
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Keywords Die life improvement, Simufact, ANOVA, Taguchi, modeling
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References
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1. Metalworking. Materials Park, OH: Bulk Forming, ASM International; 2005.
2. Sedighi M, Tokmechi S. A new approach to preform design in forging process of complex parts. J Mater Process Technol. 2008;197(1–3):314–24. doi: 10.1016/j.jmatprotec.2007.06.043.
3. Dieter GE, Bacon DJ. Mechanical metallurgy. New York: McGraw-Hill; 1986.
4. Mayur D. Improvement in hot forging process using die materials; 2014.
5. Altan T, Ngaile G, Shen G, editors. Cold and hot forging: fundamentals and applications. ASM international; 2004.
6. Tomov B, Radev R, Gagov V. Influence of flash design upon process parameters of hot die forging. J Mater Process Technol. 2004;157–158:620–3. doi: 10.1016/j.jmatprotec.2004.07.124.
7. Kim H, Sweeney K, Altan T. Application of computer aided simulation to investigate metal flow in selected forging operations. J Mater Process Technol. 1994;46(1–2):127–54. doi: 10.1016/0924–0136(94)90107–4.
8. Sedighi M, Tokmechi S. A new approach to preform design in forging process of complex parts. J Mater Process Technol. 2008;197(1–3):314–24. doi: 10.1016/j.jmatprotec.2007.06.043.
9. Tomov BI, Gagov VI, Radev RH. Numerical simulations of hot die forging processes using finite element method. J Mater Process Technol. 2004;153–154:352–8. doi: 10.1016/j.jmatprotec.2004.04.051.
10. Dieter GE, Kuhn HA, Semiatin SL, editors. Handbook of workability and process design. ASM international; 2003.
11. Krishnaiah K, Shahabudeen P. Applied design of experiments and Taguchi methods. PHI Learning Pvt. Ltd; 2012.
12. Phadke MS. Quality engineering using robust design. Prentice Hall PTR; 1995.
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Journal Menu
Editors Overview
jovdtt maintains an Editorial Board of practicing researchers from around the world, to ensure manuscripts are handled by editors who are experts in the field of study.
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- By [foreach 286]n
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Akshay S. Nandalgaonkar, Sachin C. Borse
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- Research Scholar, Assistant Professor,Deogiri Institute of Engineering and Management Studies, Deogiri Institute of Engineering and Management Studies,Aurangabad, Maharashtra, Aurangabad, Maharashtra,India, India
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Abstract
nForging 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.n
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Keywords: Die life improvement, Simufact, ANOVA, Taguchi, modeling
n[if 424 equals=”Regular Issue”][This article belongs to Journal of VLSI Design Tools & Technology(jovdtt)]
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Full Text
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Browse Figures
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References
n[if 1104 equals=””]
1. Metalworking. Materials Park, OH: Bulk Forming, ASM International; 2005.
2. Sedighi M, Tokmechi S. A new approach to preform design in forging process of complex parts. J Mater Process Technol. 2008;197(1–3):314–24. doi: 10.1016/j.jmatprotec.2007.06.043.
3. Dieter GE, Bacon DJ. Mechanical metallurgy. New York: McGraw-Hill; 1986.
4. Mayur D. Improvement in hot forging process using die materials; 2014.
5. Altan T, Ngaile G, Shen G, editors. Cold and hot forging: fundamentals and applications. ASM international; 2004.
6. Tomov B, Radev R, Gagov V. Influence of flash design upon process parameters of hot die forging. J Mater Process Technol. 2004;157–158:620–3. doi: 10.1016/j.jmatprotec.2004.07.124.
7. Kim H, Sweeney K, Altan T. Application of computer aided simulation to investigate metal flow in selected forging operations. J Mater Process Technol. 1994;46(1–2):127–54. doi: 10.1016/0924–0136(94)90107–4.
8. Sedighi M, Tokmechi S. A new approach to preform design in forging process of complex parts. J Mater Process Technol. 2008;197(1–3):314–24. doi: 10.1016/j.jmatprotec.2007.06.043.
9. Tomov BI, Gagov VI, Radev RH. Numerical simulations of hot die forging processes using finite element method. J Mater Process Technol. 2004;153–154:352–8. doi: 10.1016/j.jmatprotec.2004.04.051.
10. Dieter GE, Kuhn HA, Semiatin SL, editors. Handbook of workability and process design. ASM international; 2003.
11. Krishnaiah K, Shahabudeen P. Applied design of experiments and Taguchi methods. PHI Learning Pvt. Ltd; 2012.
12. Phadke MS. Quality engineering using robust design. Prentice Hall PTR; 1995.
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Journal of VLSI Design Tools & Technology
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Volume | 11 |
Issue | 1 |
Received | March 24, 2021 |
Accepted | April 1, 2021 |
Published | April 15, 2021 |
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