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Work-piece optimization and thermal analysis for flash-less cold forging of AUV
propeller hubs — FEM simulation and experiment
H.M.T. Khaleed ∗ , Z. Samad, A.R. Othman, M.A. Mujeebu, A.B. Abdullah, M.M. Zihad
School of Mechanical Engineering, Universiti Sains Malaysia, Engineering Campus, 14300 Nibong Tebal, Penang, Malaysia
1. Introduction algorithm to determine the initial billet geometry for the forged
products using a function approximation. Xu and Rao [7] carried
In a metal forming process, work-piece optimization plays an out an analysis of isothermal axisymmetric spike-forging using
important role in minimizing the production cost and time, while an integrated FEM code. The influence of different geometric
ensuring maximum accuracy. Flash and under-filling are common parameters, processing variables and interfacial conditions on the
issues in manufacturing processes such as forging, casting, molding instantaneous spike height were studied. Hsu and Lee [8] proposed
etc; these two crucial problems can be effectively solved by proper an ANN based cold forging process design method suitable for
design and optimization of the work-piece. Substantial studies the shop floor to decide the cold forging process parameters for
have been carried out in this area and are still underway, using producing a sound product within the required minimum quantity
modern computer-aided tools and techniques such as the finite of the die set.
element method (FEM), artificial neural networks (ANNs) and Falk et al. [9] analyzed the applicability of different failure
many others. A brief review of the previous works on cold forging concepts for a closed cold forging die. The critical, process-
which is the focus of the preset study, is presented here. dependent load was quantified and localized by using FEM. Lee
A computer-aided system called ‘‘FORMING’’ for designing et al. [10] developed a computer aided design (CAD) system
the forming sequence for multistage forging of round parts was using Auto-Lisp and three die-design modules namely, forward
presented by Badawy et al. [1]. FEM simulation and experiments extrusion, upsetting and combined extrusion were presented. Im
to understand the dimensional difference between forging tools et al. [11] introduced a process design technique based on a forging
and forged components was reported by Natsume et al. [2]. simulator and commercial CAD software for the cold forging of ball
Meidert et al. [3] presented FEM modeling with plasticine, for joints.
the process design of cold forging. Oh et al. [4] has demonstrated Qin et al. [12] worked to combine coupled thermo-mechanical
the capability of the DEFORM system in handling cold forging FE plastic simulation and heat transfer analysis to define heat-
flux–density functions across die/work piece interfaces. Flash-
problems. Duggirala et al. [5] introduced a method for design
less cold forging of an aluminium connecting rod was studied by
optimization of process variables in cold forging sequences. To
Vazquez and Altan [13] using the DEFORM-FEM package. Ishikawa
minimize the possibility of the initiation of tensile fracture in the
et al. [14] studied analytically the effects of forming stresses
outer race pre-form of a constant velocity joint, an adaptive Micro
and heat generation on the dimensional accuracy of punch, die
Genetic Algorithm was implemented, and a significant reduction
and work piece during forging. Hussain et al. [15] presented a
in the maximum damage value was achieved. Kim et al. [6] used
numerical study on the forming of a clutch-hub using a CAD
a three-layer neural network trained by the back-propagation
simulation tool CAMPform. Simulations for S10C steel using various
die and work-piece geometries were carried out to determine the
most suitable forming condition for production. Lee et al. [16]
∗ Corresponding author. Tel.: +60 45996369. evaluated the characteristics of elastic deformation at a forming
E-mail address: khalid_tan@yahoo.com (H.M.T. Khaleed). tool for a cold forged alloyed steel by experimental and FEM
1526-6125/$ – see front matter © 2010 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
doi:10.1016/j.jmapro.2010.10.003
42 H.M.T. Khaleed et al. / Journal of Manufacturing Processes 13 (2011) 41–49
Table 1
Properties of work-piece die, punch and other mountings.
Parameter Work-piece Die Punch Die insert Plates
analysis. Kim et al. [17] used rigid-plastic FEM simulation of 2.2.2. Constitutive equations
forming of impeller hub, to analyze the deformation characteristics
and to optimize the process. Ohashi et al. [18] developed a CAD
system to design forging sequences and die profiles. The process 2σ 3 ′ ′
σ ′ ij = ε̇ij σ = σ ij σ ij .ε̇(ε̇ij ε̇ij ). (3)
design for closed-die forging of a bevel gear used in automobile 3 ε̇ 2
transmission system was made by Song and Im [19] using FEM. σ and ε̇ are the effective stress and the effective strain velocity ε̇ij
Khaleed et al. [20,21] has carried out stress analysis for bolted joint is the strain velocity and σ ′ ij is a deviatory stress component.
and optimization of a blade pre-form.
As far the forming of complex geometries is such as propeller
2.2.3. Boundary conditions
hubs and blade is concerned only few works have been reported.
For instance, the manufacturing of a propeller using Verton long
glass fibre reinforced polyamide thermoplastics was reported by σijni = Fj on SF , ui = U i on SU . (4)
Geoffrey and Vickers [22] who employed injection molding. The ni is material’s rate of change, Fj denotes the force on the boundary
hot forging of aerofoil blades was performed by Hu et al. [23] surface of SF and Ui denotes the deformation velocity on the
who modeled smooth Bezier surfaces using Abaqus/Explicit FE boundary surface of SU .
software. Recently, Cheng and Lai [24] used the shape deposition The basic mathematical equations are as follows by Altan and
manufacturing process for the propellers with smooth surfaces. Knoerr [3]:
However, as far the authors are aware, no literature is available ∫ ∫
on the manufacturing of autonomous underwater vehicle (AUV)
π= σ ε̇dV − ti vi dS (5)
propellers and other propellers using cold forging. Against this sF
background, the present study focuses on the flash-less cold
where the traction ti is specified on the boundary SF and vi is the
forging of front and back hubs of an AUV propeller, using FEM
velocity component dV and dS are the volume and surface area of
simulation and experiment. In the simulation part, the work-piece
material.
optimization and thermal analysis are performed for the flash-less
The incompressibility constraint on admissible velocity fields
cold forging of the front and back hubs and the simulated samples
may be removed by introducing a penalty constant K and
are fabricated using a 100 ton C-type machine.
modifying the functional (Eq. (5)). Then, the solution of the original
boundary-value problem is obtained from the solution of the
2. Materials and methods
dual variational problem, where the first order variation of the
functional vanishes [16].
2.1. Material properties for die, punch and mountings ∫ ∫ ∫
The material properties chosen for the current study are shown δΠ = σ δ ε̇dV − ti δvi dS + K ϵ̇v δ ϵ̇v dV = 0 (6)
v sF v
in Table 1. Aluminium is selected for the work-piece owing to
its suitability for corrosive underwater environment and its good where δvi is the arbitrary variation where as δ ε̇ , and δ ϵ̇v are the
formability. The yield strength values given are all in compression. variations in strain rate from δvi , ϵ̇v is the volumetric strain rate.
The hardness values of the components are chosen based on the Eq. (6) can be converted to a nonlinear algebraic equation by us-
working stresses. ing finite element discretization. Using a numerical technique such
as the Newton–Raphson, the solution for nonlinear simultaneous
2.2. Finite element formulation equations can be obtained. In this study DEFORM 3D V 6.1 is used
for metal forming simulation.
In cold forging elastic deformation can be neglected and the
material is considered as rigid plastic [3,16]. Therefore in this study, 2.3. FEM simulation model
the rigid-plastic finite element method is applied for analysis of
deformation. The basic equations of the rigid-plastic finite element The front and back hubs of the AUV propeller are modeled
are as follows [3]. The work-piece is assumed to obey the von- by SOLID WORKS SP47.2007 and assembled using an assembly
Mises yield criterion and its associate flow rule; the stress and module and saved as an STL file. Then all the STL files are imported
strain field solutions satisfy the Equilibrium equations. to DEFORM-F3 3D software, the simulation is run and the results
are observed. If flash occurs in the work piece, the next step
2.2.1. Equilibrium equation is to optimize the work-piece to avoid the flash. Accordingly
simulations are repeated until no flash is found. For the no-flash
work-piece, if effective stresses are found more than the yield
σij,j = 0 (1) then the parameters are changed until no plastic element is found.
where σij,j are the actual stress components The velocity of the punch is 250 mm/s, the friction coefficient is
Strain rate-velocity relation and incompressibility condition: 0.15, the initial temperature of the work-piece, punch and die is
25 °C, the punch stroke is 14.4 mm, the number of steps is 100
1
ε̇ij = ui ,j + uj ,i ε̇v = uii = 0. (2) and the step increment is 10. For the die stress, the size ratio
2 is 3, the interpolation force tolerance is 0.0001 and the bottom
ε̇ij is the strain velocity, ui,j , uj,i , uii are deformation velocities and surface of the die is constrained in the X , Y and Z directions. The
ε̇v is the strain velocity component. starting step number is 1, the number of simulation steps is 1, the
H.M.T. Khaleed et al. / Journal of Manufacturing Processes 13 (2011) 41–49 43
Vwp = Vf . (7)
3. Simulation results and discussion
Substituting the values of the final dimensions of the work-piece,
Eq. (7) reduces to: 3.1. Under-filling and flash
1
π r12 L1 − h × (A2 − A3 ) = Vf (8)
2 3.1.1. Front hub
1 The results are obtained from simulations for five cases, namely,
2
h × (A2 − A3 ) + Vf
L1 = (9) I–V on the basis of varying the diameter (radius r1 ) of the work-
π r12 piece as 25–29 mm respectively for a fixed length (L1 ) of 26 mm.
For each case the simulation is run, and under-filling and flash are
2 × Vf − h × π r22 observed by using the ‘‘slice’’ option, at the center of the forged
r1 = (10)
π (2L1 − h) assembly, as shown in Figs. 3–7 respectively. Further, the volumes
5
26
15
6
28 29.40
Table 2
Simulation result summary of front hub for various cases.
Cases Work-piece volume (mm3 ) Cavity volume (mm3 ) Flash Under-filling
4. Thermal analysis
Table 3
Simulation result summary of back hub for various cases.
Cases Work-piece volume (mm3 ) Cavity volume (mm3 ) Flash Under- filling
Fig. 10. Cross-section view of back hub formation for case III.
Fig. 13. Temperature distribution in front hub during forging for Case III.
Fig. 11. Cross-section view of back hub formation for case IV.
the tolerable limit. For the front hub, the maximum temperature
is observed at the bottom surfaces of the blind holes and the Fig. 14. Temperature vs time graph during forging process for Case III.
Table 5
Machine specifications.
Item Specification
Fig. 17. The C-type forging machine used in the current study.
6. Experimental results
a b
Table 6
Comparison of designed and experimental dimensions of front hub.
*
Dimension (mm) H = 25.00 D = 30.00 d1 = 5.00 h1 = 3.00 d2 = 7.00 h2 = 3.00
Designed tolerance (mm) ±0.25 ±0.25 ±0.10 ±0.10 ±0.15 ±0.10
Case I Forged 24.50 29.29 5.34 2.86 6.67 2.91
Deviation 0.50 0.71 0.34 0.14 0.33 0.09
CaseIII Forged 24.78 29.85 5.09 2.92 6.89 2.93
Deviation 0.22 0.15 0.09 0.08 0.11 0.07
Case IV Forged 24.80 29.91 5.08 2.97 6.98 2.95
Deviation 0.20 0.09 0.08 0.03 0.02 0.05
*
Outside diameter of the final product. @Refer Fig. 18.
Table 7
Work-piece volume, flash volume and under-filling volume of front hub for various cases.
Cases Diameter Height Work-piece volume (mm3 ) DEFORM Flash observed (mm3 ) Under filling observed (mm3 )
Underfilling
Case I
Underfilling
Case III
and V are tested, and Fig. 21 shows the corresponding experimental
forged samples. Exactly similar to the predictions, case I is observed
to be the best as it has acceptable under-filling of 171.34 mm3 with
flash of 40.5 mm3 , minimum flash and load. The deviation for this
case is also within the tolerable limit, as illustrated in Table 8. It
Minimum is worth noting that the capsule-shaped hole at the bottom of the
Flash Underfilling back hub is also formed in a single operation. Table 9 shows the
work-piece, flash volume and under-filling volumes of back hub
for cases I, III and V. The case I produces less flash and under-filling
is within the tolerable limit; hence, this is the optimum.
Case IV 7. Conclusion
Table 8
Comparison of designed and experimental dimensions of back hub.
*
Dimension (mm) d = 30.00 a = 6.00 b = 10.00 c = 5.00 d = 15.00 E = 15.00
Designed tolerance (mm) ±0.25 ±0.25 ±0.10 ±0.10 ±0.15 ±0.10
Case I Forged 29.79 6.11 10.20 5.05 14.89 15.09
Deviation 0.21 0.11 0.20 0.15 0.11 0.09
CaseIII Forged 29.87 6.10 10.17 5.09 14.97 15.06
Deviation 0.13 0.10 0.17 0.19 0.03 0.06
Case V Forged 29.94 6.01 10.04 4.96 14.99 15.03
Deviation 0.06 0.01 0.04 0.06 0.01 0.03
*
Outside diameter of the final product. @Refer Fig. 20.
Table 9
Work-piece volume, flash volume and volume of under-filling of back hub for various cases.
Cases Work-piece diameter Blind hole diameter Work-piece volume (mm3 ) Flash observed (mm3 ) Under filling observed (mm3 )
Flash Zoomed
Flash
view Zoomed view
(a) Case I. (b) Case III.
Flash
Zoomed view
(c) Case V.
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