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Thermo-mechanically coupled FE analysis and sensitivity study of simultaneous hot/cold forging process with local inductive heating and cooling

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Abstract

The numerical investigation of the production of a stub shaft is presented, where the highly innovative metal forming technology of the simultaneous hot and cold forging is applied in combination with a hardening process performed directly in the closed forging dies after the forging step similar to press hardening of sheet metal. This complex forging process is completely analysed by means of a finite element simulation including the local inductive heating phase of the workpiece as well as the cooling process of the final stub shaft inside the forging dies. All relevant process parameters and the whole simulation model are documented in detail and the simulation results are discussed and validated by means of experimentally measured data, showing good agreement. Parameter studies for various properties of the model are carried out in order to investigate their influence on the geometry and the temperature field development, whereby a deeper understanding of the entire process is gained. Thus, a finite element benchmark analysis is provided for such a complex thermo-mechanically coupled structuring process.

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Notes

  1. No continuous optical analysis of the inhomogeneous necking of the specimen is available with the current experimental set up. However, the course of the flow curves can be derived from the tension test data (see Fig. 8). For this purpose, the deformed geometry of the specimens is measured after testing in order to determine the uniform elongation und the diameter of the area of fracture. Hence, the true–stress vs. true–strain course can be determined for the range of uniform elongation. Furthermore, in the case of sudden fracture at low temperture levels, the final deformation and the related Cauchy–stress can be calculated for the configuration at fracture. For an estimation of the course of the flow curve between the range of uniform elongation and the point of fracture of the specimen, a physically reasonable interpolation is made for the development of the reduction of the cross section by means of an appropriate mathematical function. In the case at hand, the cosine–function in the first quadrant of the coordinate system is chosen as the interpolant.

  2. The test data is kindly provided by Prof. Scholtes, Institute of Materials Engineering, University of Kassel, Kassel/Germany.

  3. The experimental data is kindly provided by Prof. Steinhoff, Institute of Production Technology and Logistics, Chair of Metal Forming Technology, University of Kassel, Kassel/Germany.

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Acknowledgements

This publication is based on research activities of the collaborative research centre SFB/TR TRR 30, kindly supported by the German Research Foundation (DFG).

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  1. Institute of Mechanics, Department of Mechanical Engineering, University of Kassel, Moenchebergstr. 7, 34125, Kassel, Germany

    Anton Matzenmiller & Christoph Bröcker

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  1. Anton Matzenmiller
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  2. Christoph Bröcker
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Correspondence to Anton Matzenmiller.

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Matzenmiller, A., Bröcker, C. Thermo-mechanically coupled FE analysis and sensitivity study of simultaneous hot/cold forging process with local inductive heating and cooling. Int J Mater Form 5, 275–300 (2012). https://doi.org/10.1007/s12289-011-1042-y

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