August 2019 Volume 1

FORGING RESEARCH

1.1. Introduction................................................................................................................................................................................12 1.2. Objectives ..................................................................................................................................................................................15 1.3. Approaches.................................................................................................................................................................................16 1.4. Report Organization...................................................................................................................................................................17 Chapter 2..................................................................................................................................................................................................18 Development and Evaluation of the Forging Process for Hollow Axle Shaft.............................................................................................18 2.1. Introduction. ..............................................................................................................................................................................18 2.2. Proposed Forging Sequence for Hollow Axle Shaft.....................................................................................................................19 2.3. Metal Flow Pattern and Process Feasibility ................................................................................................................................21 2.4. FEModeling...............................................................................................................................................................................26 2.5. Application of the Differential heating based Forming Process to Shafts with Various Inner Diameters .................................... 31 2.6. Concluding Remarks..................................................................................................................................................................33 Chapter 3..................................................................................................................................................................................................35 Optimization of the Forging Process for Hollow Axle Shaft .....................................................................................................................35 3.1. Introduction................................................................................................................................................................................35 3.2. Die Design Improvement and Reduction of Load Exerted by Pseudo dies .................................................................................35 3.3. Ironing operation to achieve uniformwall thickness. .................................................................................................................39 3.3.1. FEMModeling.................................................................................................................................................................40 3.3.2. FE Simulation Results......................................................................................................................................................40 3.4. Concluding Remarks..................................................................................................................................................................42 Chapter 4..................................................................................................................................................................................................44 Development and Evaluation of the Forging Process for the HollowMain Shaft......................................................................................44 4.1. Progressive Forging Sequence......................................................................................................................................................45 4.2. FEModeling. .............................................................................................................................................................................47 4.3. Metal Flow Pattern and Process Feasibility.................................................................................................................................49 4.4. Effect of the Inner Diameter and Heated Volume on the Preform Shapes...................................................................................55 4.5. Issue with the Metal Flow of the HollowMain Shaft..................................................................................................................57 4.6. Optimization of Die Design.......................................................................................................................................................59 4.7. Concluding Remarks..................................................................................................................................................................62 Chapter 5.................................................................................................................................................................................................. 63 Development and Evaluation of the Forging Process for the Hollow Pinion Gear Shaft............................................................................63 5.1. Progressive Forging Sequence......................................................................................................................................................64 5.2. FEModeling...............................................................................................................................................................................67 5.3. Metal Flow Pattern and Process Feasibility.................................................................................................................................70 5.4. Optimization of the Forging Sequence.......................................................................................................................................73 5.4.1. Sequence 1: Extrusion Stage before the Differential heating based Forging Process..........................................................73 5.4.2. FEModeling of Sequence 1..............................................................................................................................................74 5.4.3. FE Simulation Results of Sequence 1................................................................................................................................77 5.4.4. Sequence2 : Extrusion Stage in the middle of the Differential heating based Forging Process..........................................77 5.5. Concluding Remarks..................................................................................................................................................................80 Chapter 6..................................................................................................................................................................................................81 Development of Evaluation of the Forging Process for Hollow Gear or Layshaft......................................................................................81 6.1. Progressive Forging Sequence for Hollow Layshafts....................................................................................................................82

FIA MAGAZINE | August 2019 49