Skip to main content
SpringerLink
Log in

Automatic and precise simulation of multistage automatic cold-forging processes by combined analyses of two- and three-dimensional approaches

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

We applied a combined two- and three-dimensional (2D and 3D, respectively) simulation techniques to analyze a sequence of multistage automatic cold-forging processes. After discussing recent forging simulation technology, a rigid-plastic finite element-based forging simulator known as AFDEX was introduced. A five-stage cold-forging sequence was 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. The importance of using a combined 2D and 3D simulation was illustrated in terms of the solution precision and accuracy, and computational efficiency.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Lee CH, Kobayashi S (1973) New solutions to rigid-plastic deformation problems using matrix method. J Eng Ind Trans ASME 95:865–873

    Google Scholar 

  2. Li G, Jinn JT, Wu WT, Oh SI (2001) Recent development and applications of three-dimensional finite element modeling in bulk forming processes. J Mater Process Technol 113:40–45

    Article  Google Scholar 

  3. Na JW, Rhim SH, Oh SI (2007) Prediction of birefringence distribution for optical glass lens. J Mater Process Technol 187–188:407–411

    Article  Google Scholar 

  4. Boussetta R, Coupez T, Fourment L (2006) Adaptive remeshing based on a posteriori error estimation for forging simulation. Comput Meth Appl Mech Eng 195:6626–6645

    Article  MATH  MathSciNet  Google Scholar 

  5. Chenot J-L, Massoni E (2006) Finite element modelling and control of new metal forming processes. Int J Mach Tools Manuf 46:1194–1200

    Google Scholar 

  6. Joun MS, Lee MC (1998) Quadrilateral finite-element generation and mesh quality control for metal forming simulation. Int J Numer Methods Eng 40:4059–4075

    Article  Google Scholar 

  7. Hattangady NV (1999) Automatic remeshing in 3-D analysis of forming processes. Int J Numer Methods Eng 45:553–568

    Article  MATH  Google Scholar 

  8. Son I-H, Im Y-T (2006) Localized remeshing techniques for three-dimensional metal forming simulations with linear tetrahedral elements. Int J Numer Methods Eng 67:672–696

    Article  MATH  Google Scholar 

  9. Cho JR, Lee N-K, Yang D-Y (1993) Three-dimensional simulation for non-isothermal forging of a steam turbine blade by the thermoviscoplastic finite element method. Proc Inst Mech Eng Part B-J Eng Manuf 207:265–273

    Article  Google Scholar 

  10. AFDEX, http://www.afdex.com or http://engine.gsnu.ac.kr/

  11. EESY-2-FORM, http://www.cpmgmbh.de

  12. DEFORM, http://www.deform.com

  13. FORGE, http://www.transvalor.com

  14. Superforge, Superform, http://www.mscsoftware.com

  15. QForm, http://www.quantor.com

  16. Im CS, Suh SR, Lee MC, Kim JH, Joun MS (1999) Computer-aided process design in cold-former forging using a forging simulator and a commercial CAD software. J Mater Process Technol 95:155–163

    Article  Google Scholar 

  17. Moon HK, Lee JS, Yoo SJ, Joun MS, Lee JK (2007) Hot deformation behavior of bearing steels. J Eng Mater Technol Trans ASME 129:349–355

    Article  Google Scholar 

  18. Ryu CH, Joun MS (2001) Finite element simulation of the cold forging process having a floating die. J Mater Process Technol 112:121–126

    Article  Google Scholar 

  19. Joun MS, Moon HK, Shivpuri R (1998) Automatic simulation of a sequence of hot-former forging processes by a rigid thermo-viscoplastic finite element method. J Eng Mater Technol Trans ASME 120:291–296

    Article  Google Scholar 

  20. MacCormack C, Monaghan J (2002) 2D and 3D finite element analysis of a three-stage forging sequence. J Mater Process Technol 127:48–56

    Article  Google Scholar 

  21. Behrens A, Schafstall H (1998) 2D and 3D simulation of complex multistage forging processes by use of adaptive friction coefficient. J Mater Process Technol 80–81:298–303

    Article  Google Scholar 

  22. Joun MS, Lee MC, Chung SH, Kwon YS (2004) Consideration on the results of metal forming simulation based on MINI-elements. Kor Soc Mech Eng (A) 28:1475–1482

    Google Scholar 

  23. Lee MC, Joun MS (2008) Adaptive triangular element generation and optimization-based smoothing, Part 1: On the plane. Adv Eng Softw 39:25–34

    Article  Google Scholar 

  24. Lee MC, Joun MS (2008) Adaptive triangular element generation and optimization-based smoothing: Part 2. On the surface. Adv Eng Softw 39:35–46

    Article  Google Scholar 

  25. Lee MC, Joun MS, Lee JK (2007) Adaptive tetrahedral element generation and refinement to improve the quality of bulk metal forming simulation. Finite Elem Anal Des 43:788–802

    Article  Google Scholar 

  26. Kobayashi S, Oh SI, Altan T (1989) Metal forming and the finite element method. Oxford University Press, New York, USA

    Google Scholar 

  27. Chenot J-L, Bay F (1998) An overview of numerical modeling techniques. J Mater Process Technol 80–81(1):8–15

    Article  Google Scholar 

  28. Talbert JA, Parkinson AR (1990) Development of an automatic, two-dimensional finite element mesh generator using quadrilateral elements and Bezier curve boundary definition. Int J Numer Methods Eng 29:1551–1567

    Article  Google Scholar 

  29. Blacker TD, Stephenson MB (1991) Paving. A new approach to automated quadrilateral mesh generation. Int J Numer Methods Eng 32:811–847

    Article  MATH  Google Scholar 

  30. Owen SJ, Staten ML, Canann SA, Saigal S (1999) Q-Morph: an indirect approach to advancing front quad meshing. Int J Numer Methods Eng 44:1317–1340

    Article  MATH  Google Scholar 

  31. Schneiders R (1996) A grid-based algorithm for the generation of hexahedral element meshes. Eng Comput 12:168–177

    Article  Google Scholar 

  32. Dhondt GD (2001) Unstructured 20-node brick element meshing. Comput-Aided Des 33:233–249

    Article  Google Scholar 

  33. Tautges TJ, Blacker T, Mitchell SA (1996) The whisker weaving algorithm: a connectivity-based method for constructing all-hexahedral finite element meshes. Int J Numer Methods Eng 39:3327–3349

    Article  MATH  MathSciNet  Google Scholar 

  34. Price MA, Armstrong CG (1997) Hexahedral mesh generation by medial surface subdivision: Part II. Solids with flat and concave edges. Int J Numer Methods Eng 40:111–136

    Article  Google Scholar 

  35. Owen SJ, Saigal S (2000) H-Morph: an indirect approach to advancing front hex meshing. Int J Numer Methods Eng 49:289–312

    Article  MATH  Google Scholar 

  36. Brezzi F, Fortin M (1991) Mixed and hybrid finite element methods. Springer, Berlin Heidelberg New York

    MATH  Google Scholar 

  37. Zienkiewicz OC, Taylor RL (2000) The finite element method, 5th edn. Butterworth-Heinemann, Oxford

    Google Scholar 

  38. Arnold DN, Brezzi F, Fortin M (1984) A stable finite element for Stokes equations. Calcolo 21(4):337–344

    Article  MATH  MathSciNet  Google Scholar 

  39. Babuška I (1973) The finite element method with Lagrangian multipliers. Numer Math 20:179–192

    Article  MATH  Google Scholar 

  40. Brezzi F (1974) On the existence, uniqueness and approximation of saddle-point problems arising from Lagrange multipliers. Math Model & Numer Anal 21:129–151

    MathSciNet  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Gyeongsang National University, Jinju-city, 660-701, Republic of Korea

    M. C. Lee

  2. Hyundai-Steel Co. Ltd., 283 Eumnae-ri, Dangjin-gun, Chungnam, 343-805, Republic of Korea

    S. H. Chung

  3. School of Mechanical and Aerospace Engineering, Gyeongsang National University, 900 Gazwa-dong, Jinju-city, Gyeongnam, 660-701, Korea

    M. S. Joun

  4. Research Center for Aircraft Parts Technology, Gyeongsang National University, Jinju-city, 660-701, Republic of Korea

    M. S. Joun

Authors
  1. M. C. Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. S. H. Chung
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. M. S. Joun
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to M. S. Joun.

Additional information

The English in this document has been checked by at least two professional editors, both native speakers of English. For a certificate, see: http://www.textcheck.com/cgi-bin/certificate.cgi?id=pH2Rdb

Rights and permissions

Reprints and permissions

About this article

Cite this article

Lee, M.C., Chung, S.H. & Joun, M.S. Automatic and precise simulation of multistage automatic cold-forging processes by combined analyses of two- and three-dimensional approaches. Int J Adv Manuf Technol 41, 1–7 (2009). https://doi.org/10.1007/s00170-008-1445-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-008-1445-1

Keywords

Search

Navigation