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Tetrahedral elements were used to mesh the grid number of 10,000 and the complete cold forging simulation was performed in 120 steps with displacements for the movement of the top die in each step of 0.15 mm.
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In this paper a comprehensive approach is presented for the consideration of the interactions between process, tool and machine during the design of cold forging tools and processes by simulation.
On the basis of theoretical knowledge on process design, numerical simulation of the cold forging operation has been carried out using the commercial finite element software, DEFORM.
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.
Similar to the simulated results, the experiment on cold forging a 5052 aluminum alloy sprocket was successfully performed.
The simulation can be used to determine the initial tool dimensions for precision parts in the tool design process of cold forging.
The performance evaluation of cold forging lubricants and coatings as well as determination of the friction coefficients is necessary for production as well as finite element (FE) simulations.
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.
However, recent research and previous studies using finite element (FE) simulation as well as experiments indicated that the interface pressure conditions and surface generation in the DCET may not be comparable to those found in cold forging.
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