Skip to main content
SpringerLink
Log in

Optimized Design for a Combined Die with Two Stress Rings in Cold Forging Considering Thermal-Mechanical Effects

  • Published:
Journal of Shanghai Jiaotong University (Science) Aims and scope Submit manuscript

Abstract

Stress analysis and optimization of combined die structure with two stress rings were performed. Using thermoelastic deformation, the contact pressure at the interfaces between layers was calculated. Then, theoretical expressions of stress distribution for the combined die were derived. The thermal-mechanical effect under working conditions was considered. To verify the theoretical expressions, simulation work was performed. Optimization of die design was carried out by defining radius ratio and shrink fit coefficient as optimization variables. The objective was to minimize the effective circumferential stress at the inner surface of the die insert, under the constraint that the maximum equivalent stress values of die insert and stress rings did not exceed their respective yield stresses. The Kriging model was used to describe the influence of shrink fit and die dimensions on the objective function and the maximum equivalent stress. Using a genetic algorithm, optimum parameters were found with a minimum circumferential stress of 442.9MPa under a working stress of 1 800MPa. Further analysis of five selected optimal results was carried out, and the specific design parameters of these combined dies are different under the same level of circumferential stress, and the combined die is overdesigned if the thermal effect is ignored.

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

Abbreviations

E j :

Elasticity modulus of each layer (j = 1, 2, 3)

h e :

Convection coefficient between die and environment

h w :

Coefficient of heat conduction between workpiece and die

p 0 :

External stress at inner surface of combined die

p 1 :

External stress at outer surface of combined die

p :

Working stress on the inner surface of the combined die

p k1 :

Contact stress between die insert and stress ring 1

p k2 :

Contact stress between stress ring 1 and stress ring 2

r :

Distance from any position in combined die to the symmetry axis of the die

r 1 :

Inner radii of first layer

r 2 :

Outer radii of first layer

r 3 :

Inner radii of second layer

r 4 :

Outer radii of second layer

r 5 :

Inner radii of third layer

r 6 :

Outer radii of third layer

r e :

Outer radii of third layer after thermal deformation

r i :

Inner radii of first layer after thermal deformation

r j h :

Radii of each layer of the combined die after thermal expansion (j =1, 2, 3, 4, 5, 6)

t e :

Environment temperature

t i :

Temperature at the inner surface of first layer

t m :

Temperature at the interface between die insert and stress ring 1

t o :

Temperature at the outer surface of third layer

t w :

Temperature of workpiece

u rj h :

Thermo-elastic deformations of each radius

α :

Coefficient of thermal expansion

λ 1 :

Coefficient of thermal conductivity of first layer

λ 2 :

Coefficient of thermal conductivity of second/third layer

μ j :

Poisson’s ratio of each layer (j = 1, 2, 3)

σr(ri):

Total radial stress in ri

σ′r(ri):

Radial stress generated by shrink fit in ri

σ″r(ri):

Radial stress generated by working stress in ri

σ̄ r i :

Equivalent stress in ri

σt(ri):

Total circumferential stress in ri

σ′t(ri):

Circumferential stress generated by shrink fit in ri

σ″t(ri):

Circumferential stress generated by working stress in ri

i :

The surface of different layers

j :

The number of layer

References

  1. DODD B. Introduction to cold forging [EB/OL]. [2018-07-27]. https://www.icfg.info/general-information/cold-forging.html.

    Google Scholar 

  2. FUJIKAWA S, YOSHIOKA H, SHIMAMURA S. Cold- and warm-forging applications in the automotive industry [J]. Journal of Materials Processing Technology, 1992, 35(3/4): 317–342.

    Article  Google Scholar 

  3. BAY N. The state of the art in cold forging lubrication [J]. Journal of Materials Processing Technology, 1994, 46(1/2): 19–40.

    Article  Google Scholar 

  4. MACCORMACK C, MONAGHAN J. Failure analysis of cold forging dies using FEA [J]. Journal of Materials Processing Technology, 2001, 117(1/2): 209–215.

    Article  Google Scholar 

  5. KOC M, ARSLAN M A. Design and finite element analysis of innovative tooling elements (stress pins) to prolong-die life and improve dimensional tolerances in precision forming processes [J]. Journal of Materials Processing Technology, 2003, 142(3): 773–785.

    Article  Google Scholar 

  6. YEO H T, CHOI Y, HUR K D. Analysis and design of the prestressed cold extrusion die [J]. The International Journal of Advanced Manufacturing Technology, 2001, 18(1): 54–61.

    Article  Google Scholar 

  7. CHEN X, BALENDRA R, QIN Y. A new approach for the optimisation of the shrink fitting of cold-forging dies [J]. Journal of Materials Processing Technology, 2004, 145(2): 215–223.

    Article  Google Scholar 

  8. KROI T, ENGEL U, MERKLEIN M. Comprehensive approach for process modeling and optimization in cold forging considering interactions between process, tool and press [J]. Journal of Materials Processing Technology, 2013, 213(7): 1118–1127.

    Article  Google Scholar 

  9. ZHANG Y, ZHOU J, HU Q G. Optimization design of combined die for cold extrusion based on particle swarm optimization [J]. Hot Working Technology, 2010, 39(3): 95–97 (in Chinese).

    Google Scholar 

  10. KWAN C T, WANG C C. An optimal pre-stress die design of cold backward extrusion by RSM method [J]. Structural Longevity, 2011, 5(1): 25–32.

    Google Scholar 

  11. JUN B Y, KANG S M, LEE M C, et al. Prediction of geometric dimensions for cold forgings using the finite element method [J]. Journal of Materials Processing Technology, 2007, 189(1/2/3): 459–465.

    Article  Google Scholar 

  12. ISHIKAWA T, YUKAWA N, YOSHIDA Y, et al. Prediction of dimensional difference of product from tool in cold backward extrusion [J]. CIRP Annals-Manufacturing Technology, 2000, 49(1): 169–172.

    Article  Google Scholar 

  13. LONG H, BALENDRA R. FE simulation of the influence of thermal and elastic effects on the accuracy of cold-extruded components [J]. Journal of Materials Processing Technology, 1998, 84(1/2/3): 247–260.

    Article  Google Scholar 

  14. KHALEED H M T, SAMAD Z, OTHMAN A R, et al. Work-piece optimization and thermal analysis for flash-less cold forging of AUV propeller hubs: FEM simulation and experiment [J]. Journal of Manufacturing Processes, 2011, 13(1): 41–49.

    Article  Google Scholar 

  15. QIN Y, BALENDRA R, CHODNIKIEWICZ K. Analysis of temperature and component form-error variation with the manufacturing cycle during the forward extrusion of components [J]. Journal of Materials Processing Technology, 2004, 145(2): 171–179.

    Article  Google Scholar 

  16. HU C L, YANG F Y, ZHAO Z, et al. Thermoelastic deformation of three-layer combined die under steady-state temperature field [J]. Journal of Thermal Stresses, 2016, 39(1): 103–119.

    Article  Google Scholar 

  17. QIN Y, BALENDRA R, CHODNIKIEWICZ K. A method for the simulation of temperature stabilisation in the tools during multi-cycle cold-forging operations [J]. Journal of Materials Processing Technology, 2000, 107(1/2/3): 252–259.

    Article  Google Scholar 

  18. GROENBAEK J, BIRKER T. Innovations in cold forging die design [J]. Journal of Materials Processing Technology, 2000, 98(2): 155–161.

    Article  Google Scholar 

  19. LIU Y G, JIAO A S. Analysis and study of stress and strain of cold extruding die [J]. Journal of Lanzhou Polytechnic College, 2003, 10(1): 31–34 (in Chinese).

    Google Scholar 

  20. HU C L, ZHAO Z, ZHI Y S, et al. Thermoelastic deformation of three-layer combined die with nonuniform temperature distribution [J]. Journal of Thermal Stresses, 2014, 37(10): 1230–1243.

    Article  Google Scholar 

  21. MINASNY B, MCBRATNEY A B. A conditioned Latin hypercube method for sampling in the presence of ancillary information [J]. Computers & Geosciences, 2006, 32(9): 1378–1388.

    Article  Google Scholar 

  22. LEE H C, SAROOSH M A, SONG J H, et al. The effect of shrink fitting ratios on tool life in bolt forming processes [J]. Journal of Materials Processing Technology, 2009, 209(8): 3766–3775.

    Article  Google Scholar 

  23. JEONG S, MURAYAMA M, YAMAMOTO K. Efficient optimization design method using kriging model [J]. Journal of Aircraft, 2005, 42(2): 413–420.

    Article  Google Scholar 

  24. HOLLAND J H. Genetic algorithms [J]. Scientific American, 1992, 267(1): 66–72.

    Article  Google Scholar 

  25. JAYA SHANKAR T, BANDYOPADHYAY S. Optimization of extrusion process variables using a genetic algorithm [J]. Food and Bioproducts Processing, 2004, 82(2): 143–150.

    Article  Google Scholar 

  26. HOU E S H, ANSARI N, REN H. A genetic algorithm for multiprocessor scheduling [J]. IEEE Transactions on Parallel and Distributed Systems, 1994, 5(2): 113–120.

    Article  Google Scholar 

  27. CHUNG J S, HWANG S M. Application of a genetic algorithm to the optimal design of the die shape in extrusion [J]. Journal of Materials Processing Technology, 1997, 72(1): 69–77.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Institute of Forming Technology & Equipment, Shanghai Jiao Tong University, Shanghai, 200030, China

    Zibo Li  (李子博), Fan Zeng  (曾凡), Zhen Zhao  (赵震) & Chengliang Hu  (胡成亮)

Authors
  1. Zibo Li  (李子博)
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Fan Zeng  (曾凡)
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Zhen Zhao  (赵震)
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Chengliang Hu  (胡成亮)
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Chengliang Hu  (胡成亮).

Additional information

Foundation item: the National Natural Science Foundation of China (No. 51475294)

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Li, Z., Zeng, F., Zhao, Z. et al. Optimized Design for a Combined Die with Two Stress Rings in Cold Forging Considering Thermal-Mechanical Effects. J. Shanghai Jiaotong Univ. (Sci.) 25, 304–314 (2020). https://doi.org/10.1007/s12204-019-2150-y

Download citation

  • Received:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12204-019-2150-y

Key words

CLC number

Document code

Search

Navigation