Tooling and process design to cold forge a cross groove inner race for a constant velocity joint — physical modeling and FEM process simulation

Abstract The cross groove constant velocity joint is widely used in the automotive industry. However, the production costs of the cross groove inner race (CGIR) are relatively high due to extensive machining and grinding operations. Substituting machining by cold forging would reduce costs but also imposes new challenges due to the geometric complexity of this part. The main objectives of the present study are to investigate the material flow in cold forging a CGIR and to optimize the process using a multi-action tooling concept. In order to define and improve the process conditions, physical modeling experiments and two and three dimensional FEM process simulations were performed. This investigation was performed to determine the best tooling motion that may result in the most cost effective production process. The simulation results are expected to provide relevant information for the design of the production tooling.