FEA in optimization of progression and tool design in cold ... · 1 1 CPM Gesellschaft für...

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CPM Gesellschaft für Computeranwendung, Prozeß- und Materialtechnik

FEA in optimization of progression and tool designin cold forging

Dr. Gerhard H. Arfmann, Dr. Michael TwicklerCPM GmbH, Herzogenrath, Germany

(c) 2016 Dr. Gerhard H. Arfmann, Dr. Michael Twickler5th GAF Advanced Fastener Technology Development International Forum, 07./09.09.2016, Shanghai, PR China

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The role of FEA application in progression and tool design in cold forging

Introduction

Examples of highly engineered forged parts

Examples of improved tool design

Conclusions


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FEA in optimization of progression and tool design in cold forging

Introduction


Markets have become more and more demanding

Necessity to reduce production costs to win new orders and necessity ofcontinuous improvement of production to meet decreasing product prices

Flexibility in using the existing equipment is essential instead of big investments in new machinery that is difficult to justify and cannot be implemented quickly.

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Introduction


These requirements drive engineers to new efforts. Creative ideas and innovation is vital . New ideas to develop more sophisticated processes and tooling are needed.

This presentation will show examples of how innovative engineering can meet these challenges. All examples are real industrial production cases.

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Introduction


How to design the right process to produce a forged part?

How to design the optimum tooling?

Existing knowledge:“I think” or “I know how”

Aim of application of software tools:

I think -> I know how –> I know why

-> I can generate new know how

Tasks

Today

Target

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Production of a bolt Original progression with folding


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Production of a bolt New progression without folding


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Shock Absorber Function of the cushion system


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Shock Absorber

Function of the cushion system


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Shock Absorber



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Shock Absorber



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(c) Pedro D. Schmitt, Dr. Gerhard H. Arfmann , Luciano PinottiICFG Plenary Meeting 2016, Institut für Umformtechnik, Universität Stuttgart, Stuttgart, Germany

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Açopeças Indústria de CPM Gesellschaft fü r Computeranwendung, Peças de Aço Ltda. Prozeß- und Materi altechnik GmbH

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Special part produced with cushion system


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Prinziple of the cushion system


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Part with splines


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four stage progression

Production of a rotor from bar


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Production problem infirst operation-initial design




Production of a rotor from bar


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Design changefirst stage

old design stress analysis new design First stage new design





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First stage new design





Piercing and third stage

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First stage new design





Fourth stage

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Alternative production of the rotor from sheet metal


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Conventional production sequence using backward extrusion

Brake Piston





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Conventional backward extrusion

Load ~ 450 to

Brake Piston






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“Osen” process

Load ~ 180 to

Brake Piston






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Light weight part


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Light weight part


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Claw Pole


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Calculation of the relevant contact areas




Claw Pole


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Cut off 1. Op warm 600°C 2. Op cold calibration




Claw Pole



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Failure detection during development




Claw Pole


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Valve Tappet





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Stress analysis old and new preform – tangential stress

Valve Tappet





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Tool life improvement: initial: 16573pieces/tool optimized:222616 pieces/tool

New tool cost < 8% of the initial costs

16.573

222.616

Valve Tappet





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Six Lobe screw





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Tool breakage Stress analysis (tangential stress-positive >1.200MPa

Six Lobe screw





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Stress analysis (tangential stress-compressive ~-500MPa)

Optimizing tool design to improve the pre-stressing of the insert

400MPa -> 550 MPa

Six Lobe screw





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Tool layout overview Tool actual in production enjoyingtool life of more than 2.000.000 pieces

Six Lobe screw





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Conclusions

This presentation shows that with good engineering skills , new ideas , the willingness to try new things and

the appropriate use of existing good software tools ,

the challenges in the market can be met and overcom e.

New processes can be designed, tools may be constructed differently, and the efficiency of forming processes may be improved. Cold forging has a high potential for future develo pment still. This presentation is intended to encourage cold forging companies to be forward-thinking and to use available technology intensively. This will help them to survive in a future of increasing competition, and the growing technological demands of their clients.


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Acknowledgement

The authors would like to thank all their customers contributing to this presentation for their generous support.

Amongst others especially

Mr. Pedro Schmitt of Acopecas, Brazil

has to be mentioned for his continuous contributions.


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Thank you for your attention

Combine ideas, technology and simulation

I think -> I know how-> I know why -> I may generate new know how© AE Dr.Arfmann Engineering 2016



FEA in optimization of progression and tool design in cold ... · 1 1 CPM Gesellschaft für...

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