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Metal forming simulation with emphasis on metal flow lines using AFDEX software  There are so many kinds of failures occurring in developing metal forming processes, which are very costly and time-consuming. Under-filling or overlapping defects can be easily removed using the forging simulation software technologies. In many real situations, in fact, those defects can be…

Finite element analysis model of rotary forging for assembling wheel hubbearing assembly – Post 2/2  This post is in continuation with last week’s post on the finite element analysis model of rotary forging process of a wheel hub bearing assembly. Adding on to that introductory post, the details of the analysis model and the predictions…

Finite element analysis model of rotary forging for assemblingwheel hub bearing assembly – Post 1 This topic will be covered under a series of posts starting from this week. In the past the wheel hub bearing assembly was assembled by incredible methods which were much dependent on the manual experience. Thus, the tolerance changed from…

Enclosed die forging of an automobile differential’s bevel gear – Post 2/2 This article is a continuation to the earlier article – http://www.afdex.com/archive/blog/4 In this article, we will go further into the results and discuss this approach from a manufacturing perspective. Just a recap of the important information. The material of the bevel gear is SCM420H…

Automatic and precise simulation of multistage automatic cold-forging processes by combined analyses of two- and three-dimensional approaches A five-stage cold-forging sequence is selected as a representative example of multistage automatic forging processes because it has four axisymmetric forging stages followed by a non-axisymmetric forging stage and involves piercing and heading processes accompanying folding and overlapping.…

Enclosed die forging of an automobile differential’s bevel gear – Post 1/2 If the production of smaller size bevel gears is carried out by the closed forging method, it is advantageous in terms of quality and price. This is because the process is minimalistic and raw materials are reduced. And it has a longer die…

Consideration on metal flow lines in forging and their prediction in ring rolling after forging Metal flow lines (MFLs) or fiber flow lines are one of major factors affecting product liability and structural rigidity. It is thus essential to test the MFLs of a forging to evaluate its soundness in terms of metal forming because…

Finite element analysis of deep piercing process Aspect ratio, in the case of piercing in metal forming is the ratio between the thickness and the hole diameter which is  usually ranges between 1.0 and 1.5. In the case of deep piercing processes, the aspect ratio goes up to 5. This is challenging from the perspective…