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A new fast method called "Pseudo Inverse Approach" (PIA) for the multi-stage axi-symmetrical cold forging modelling is presented.
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Firstly, finite element method is used to simulate the cold forging process of the spur gear with two-dimensional axisymmetrical model, and the strain distributions and velocity distributions are investigated through the post processor.
The entire approach comprises an efficient determination of the deflection characteristic of stroke-controlled press and tooling system and its condensed modeling in combination with the FE simulation of a cold forging process.
Cold forging enables the manufacturing of high strength monolithic components.
Thus, the results lead to process design guidelines for cold welding by cold forging.
Cold welding, e.g. by cold forging, is a smart manufacturing technology, enabling novel multi material designs.
Deformation localisation is the main reason for material failure in cold forging of titanium alloys and is thus closely related to the production yield of cold forging.
Three different materials were tested, aluminum alloy AA6082, technically pure copper (99.5%) and cold forging steel Ma8, at different temperatures found during cold forging.
Traditional warm and cold forging methods have their own limitations to produce such a complex shaped part; warm forging requires complex system with relatively higher manufacturing cost, while cold forging is not applicable to materials with limited formability.
In the present work, residual stresses in axisymmetric cold forging process are analysed.
This work can be beneficial to process parameter optimisation and material designing for cold forging.
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