Analysis of an aluminum forging process in completely enclosed dies considering the numerical prediction of thin flash generation in small gaps

authored by: Johannes Richter, Thoms Blohm, Malte Stonis, Bernd Arno Behrens
Abstract: In the automotive industry, aluminum forged parts must fulfill lightweight and heavy duty performance requirements. The generation of thin flash between die halves and in the small gaps between the die and punch must be prevented during the flashless forging process in completely enclosed dies. However, thin flash formation is neither predictable nor preventable. A numerical model is developed based on finite element analysis to investigate and predict the generation of thin flash in aluminum flashless precision forging processes. The significance and effects of the main influencing input parameters, including billet temperature, forming velocity, and width of gap, on different resulting parameters are evaluated. Among all resulting parameters in the established numerical model, hydrostatic pressure and the forming force in the main forming direction have been identified as the most suitable for predicting thin flash generation.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Type: Article
Journal: Journal of Mechanical Science and Technology
Volume: 31
Pages: 3429-3435
No. of pages: 7
ISSN: 1738-494X
Publication date: 01.08.2017
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Mechanics of Materials, Mechanical Engineering
Electronic version(s): https://doi.org/10.1007/s12206-017-0631-y (Access: Closed)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{ee009748c08d41638783f0974f135638,
title = "Analysis of an aluminum forging process in completely enclosed dies considering the numerical prediction of thin flash generation in small gaps",
abstract = "In the automotive industry, aluminum forged parts must fulfill lightweight and heavy duty performance requirements. The generation of thin flash between die halves and in the small gaps between the die and punch must be prevented during the flashless forging process in completely enclosed dies. However, thin flash formation is neither predictable nor preventable. A numerical model is developed based on finite element analysis to investigate and predict the generation of thin flash in aluminum flashless precision forging processes. The significance and effects of the main influencing input parameters, including billet temperature, forming velocity, and width of gap, on different resulting parameters are evaluated. Among all resulting parameters in the established numerical model, hydrostatic pressure and the forming force in the main forming direction have been identified as the most suitable for predicting thin flash generation.",
keywords = "Aluminum forging, Finite element analysis, Flashless forging, Forging in completely enclosed dies",
author = "Johannes Richter and Thoms Blohm and Malte Stonis and Behrens, {Bernd Arno}",
year = "2017",
month = aug,
day = "1",
doi = "10.1007/s12206-017-0631-y",
language = "English",
volume = "31",
pages = "3429--3435",
journal = "Journal of Mechanical Science and Technology",
issn = "1738-494X",
publisher = "Korean Society of Mechanical Engineers",
number = "7",
}