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Effect of shearing on production stability and die life in automatic multi-stage cold forging of an automobile wheel nut

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Abstract

In this study, the effects of earing in a sheared billet of S25C steel formed during rod shearing in an automatic multi-stage cold forging (AMSCF) process for an automobile wheel nut were experimentally and numerically investigated. Precision forging simulations with an emphasis on rod shearing were conducted using the implicit elastoplastic finite element method with a tetrahedral MINI-element scheme. AMSCF of an automobile wheel nut involves the use of a converging or near-conical die that shows a gradual reduction in its cross-sectional area. Our results showed that the shearing-induced earing plays the role of a pivot during balancing of the material inside the die cavity in the early stroke, before significant material contact. Earing formation resulted in a wobble motion of the material that accompanied the rigid-body motion. This ultimately led to a change in the center of mass of the material and unbalanced loading. Earing had a significant influence on the local high-cycle fatigue (HCF) fracture of die insets, especially in the cold forging of nut-like short products. The stress concentration on the die was attributed to asymmetric localized contact between the material and critical die corner, leading to changes in the mass center. Taken together, our results indicate that sheared billet characterization should account for earings with roll-overs and inclined surfaces to not only better predict the HCF life of die parts but also to optimize the forging outcome, particularly for safety products such as automobile wheel nuts.

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Funding

This work was partly supported by Korea Institute of Energy Technology Evaluation and Planning (KETEP) (20214000000520, Human Resource Development Project in Circular Remanufacturing Industry) and Korea Evaluation Institute of Industrial Technology (KEIT) (20003950, Development and application of die fatigue fracture prediction system for intelligent and smart precision cold forming.) grant funded by the Korea government (MOTIE).

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Authors and Affiliations

  1. Engineering Research Institute, Graduate School of Mechanical and Aerospace Engineering, Gyeongsang National University, Jinju, Gyeongsangnam, 52828, Republic of Korea

    Jong Bok Byun & Man Soo Joun

  2. School of Mechanical and Aerospace Engineering, Gyeongsang National University, Jinju, Gyeongsangnam, 52828, Republic of Korea

    Nurhidayah Abd Hamid

  3. Korea Institute of Industrial Technology, Incheon, 21999, Republic of Korea

    Gyu Seob Cho

  4. Department of Mechanical System Design Engineering, Seoul National University of Science and Technology, Seoul, 01811, Republic of Korea

    Wan Jin Chung

  5. Technical Institute, PungKang Co., Ltd., Hwaseong, Gyeonggi, 18572, Republic of Korea

    Sung Muk Kang & Kwang Hee Lee

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  1. Jong Bok Byun
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  3. Gyu Seob Cho
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Contributions

JBB: modeling, finite element analysis. NbAH: modeling, finite element analysis. GSC: test. WJC: finite element method. SMK: experiment. KHL: experiment. MSJ: supervision.

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Correspondence to Man Soo Joun.

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Highlights

• The effects of the sheared billet on die mechanics in automatic multi-stage cold forging (AMSCF) were experimentally and numerically revealed.

• The finite element analysis model of a wheel nut AMSCF process was presented with an emphasis on the sheared billet.

• The sheared billet with the distinct earing caused the unstable and wobble motion of the material during AMSCF.

• Asymmetry of the material flow due to the shearing-induced earing brought local stress concentration around die corner during AMSCF.

• The earing-induced stress concentration caused the high-frequency fatigue fracture in the AMSCF of an automobile wheel nut.

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Byun, J.B., Hamid, N.A., Cho, G.S. et al. Effect of shearing on production stability and die life in automatic multi-stage cold forging of an automobile wheel nut. Int J Adv Manuf Technol 131, 329–341 (2024). https://doi.org/10.1007/s00170-024-13017-9

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