Geometrical Defect Evaluation of Cold Embossing AA6061 Based on FEA and Physical Modeling Technique

Geometrical defect plays a significant role to inaccuracy of the cold forging part. Defect will harm the assembly tend to affect the performance of the part. Therefore, it must be detected and minimized it as soon as the manufacturing begins. The paper presents an investigation on the geometrical defect of the cold embossing pin based FEA and physical modeling methods. The study focuses on the effect of distance to the edge (DTE) to bulging geometries. The results of both methods show a good agreement.

[1]  Donggeon Lee,et al.  New processes to prevent a flow defect in the combined forward–backward cold extrusion of a piston-pin , 2003 .

[3]  S. M. Sapuan,et al.  Geometrical Error Analysis of Cold Forged AUV Propeller Blade Using Optical Measurement Method , 2011 .

[4]  Tarras Wanheim,et al.  The basis for a design support system to prevent defects in forging , 1997 .

[5]  Henry Valberg,et al.  Physical and numerical analysis of the metal flow over the punch head in backward cup extrusion of aluminium , 2006 .

[6]  Hasan Sofuoglu,et al.  Flow behavior of Plasticine used in physical modeling of metal forming processes , 2000 .

[7]  T. Ishikawa,et al.  Modeling approach to estimate the elastic characteristics of workpiece and shrink-fitted die for cold forging , 2004 .

[8]  Taylan Altan,et al.  Material fracture and burr formation in blanking results of FEM simulations and comparison with experiments , 1996 .

[9]  Janez Kopac,et al.  Dimensional accuracy and cost optimisation in the finish machining of cold formed parts , 1999 .

[10]  Jian Lu,et al.  FE Simulation-Based Folding Defect Prediction and Avoidance in Forging of Axially Symmetrical Flanged Components , 2010 .

[11]  Tahir Altinbalik.  WITHDRAWN: A study of barreling profile and effect of aspect ratio on material flow in lateral extrusion of gear-like forms , 2007 .

[12]  Frank Vollertsen.  Accuracy in process chains using hydroforming , 2000 .

[13]  Victor Vazquez,et al.  New concepts in die design — physical and computer modeling applications , 2000 .

[14]  Kenji Hirota,et al.  Fabrication of micro-billet by sheet extrusion , 2007 .

[15]  Young Hoon Moon,et al.  Validation via FEM and plasticine modeling of upper bound criteria of a process-induced side-surface defect in forgings , 2000 .

[16]  M. Estrems,et al.  Modelling and experimental analysis of the effects of tool wear on form errors in stainless steel blanking , 2006 .