Abstract
Defects analysis and tool optimization of the hot forged automotive balance shaft were conducted based on 3D and 2D finite element (FE) simulations in order to improve forging quality and productivity. In practice, folding was observed on the forgings. 3D simulation of the whole forging process was implemented to observe the defect morphology, which was consistent with the actual. Meanwhile, the formation and thickness of folding were analyzed by using 2D simulation. According to the results, the metal flow folded into the closed ring at the stiffened rib when the metal transited through the cavity. The folding location was determined by large temperature gradient, big rotation angle, high damage value, and low metal flow velocity. The thickness of the folding was less than 5 mm. Finally, the forging tools were redesigned by increasing draft angle and fillet radius on preforging dies. Forgings without defects were obtained in simulation and practice.
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Liu, Y., Wu, Y., Wang, J. et al. Defect analysis and design optimization on the hot forging of automotive balance shaft based on 3D and 2D simulations. Int J Adv Manuf Technol 94, 2739–2749 (2018). https://doi.org/10.1007/s00170-017-1080-9
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DOI: https://doi.org/10.1007/s00170-017-1080-9