SIMULATION OF THE COLD FORGING

PROCESS IN FASTENER
MANUFACTURE
İnce Umut , Güden Mustafa
Norm Fasteners Cooperation 35620 Çiğli, İzmir, Turkey
Department of Mechanical Engineering and Dynamic Testing and Modeling Laboratory, Izmir Institute of
Technology, Gülbahçe, Urla, Izmir, Turkey

Gaurav Pandey
 FORGING PROCESS
 Forging is a manufacturing process, which shapes a work piece
by applying compressive forces on it. According to the
temperature at which is performed, forging is classified in “hot”,
“warm” and “cold”.
 Forging is a metal working process in which useful shape is
obtained in solid state by hammering or pressing metal.
 FORGING

COLD FORGING

HOT AND WARM FORGING

SIMULATION AND MODELING

 One of the primary advantages of

simulation is that they are able to provide
users with practical feedback when
designing real world systems.

 This allows the designer to determine the

correctness and efficiency of a design
before the system is actually
constructed.

 Few of the tools used for simulation are :

ANSYS,SIMUFACT,MATLAB,MARC,
ADAM etc.
SIMULATION USE IN FASTNER
MANUFACTURING
Simulation results can help to predict the
following:
 The use of method increasingly as tool in metal forming industry
result in cost reduction, time saving and improvement in product
quality.

 The simulation software in the cold forging industry show material

flow, capture the defects and allow to determine the
process parameters such as press forces, die stresses, predict
tool life and fracture.
 PURPOSE OF STUDY

 The purpose of the study is to analyze the cold

forging forming process .
 Analyze the behavior and effect of various loads
on bolts.
 Thefailure analysis of the forming die and the
work piece.
 The design analysis of the die and punch.
 INTRODUCTION
 The Norm fasteners cooperation ,turkey with the help of Izmir
institute of technology has done few case study which could
help the company advance their methods of manufacturing.
 The data in the presentation is the report of the simulation done by
the department.
 There is basically two case study done by the company , which
gives the main idea of the problem occurring.
 Along with the problems, they have also come up with the solution
to it in this paper.
 CASE STUDY-1
Lap Formation And Forging Loads

 The simulation of the model shown was done.

 The model was simulated using 2D asymmetrical

and 3D models.
RESULT OF SIMULATED MODEL
MODIFICATION

 The old and new design of 1st station as depicted

in the figure can be seen as modification.

 The new design has different shape of formation in its 1st

station .
 RESULT AND COMPARISON

INITIAL DESIGN
MODIFIED DESIGN

 It can be seen that there is no lap formation seen

after modification of design.
 The lap formation is very difficult to determine from
surface of bolt.
 Results confirmed that numerical simulation is a good tool to
to determine faulty design.
 CASE STUDY-2
COLD FORGING DIE STRESS ANALYSIS

 The figures shown above are the cold forged sequence made by progressive dies.

 The company data estimates that the dies used to manufacture these, fails after about 1000 cycles.

 In order to rectify the problem of failure of die, the forging sequence were simulated
using deformable punch die model.
SIMULATION AND RESULTS

 The simulated data shows high value of

negative principal stress at the top
of the insert.

 The results conclude that the result of failure

of die is ,the negative stress formed at surface
of insert.
MODIFICATION

 The insert material type and punch

die geometry was changed.

 The insert were changed from tool steel

to wc/co.

 The pin holes of were positioned from die to

the punch.

 The fasteners were reversed so that punch

die inserts compress less material .
RESULT AND COMPARISION

 The model gave the acceptable negative

Principal stress value.

 Before the values of stress was around

3000-3400 MPa.

 The modified model gives around

2300 MPa for WC/CO dies.
 CONCLUSIONS
 The use of finite element method as tool in metal forming industry results in cost
reduction, time saving and improvement in product quality.

 The design of deformation sequence and dies could be modeled before and also
during the production.

 These efforts allow the engineer to identify the process deficiencies easily,
leading to cost and time saving.

 The modeling efforts would be very valuable in order to verify inhomogeneous

deformations such as laps which could not be detected easily through regular
visual inspection.
HANKS FOR YOUR KIND ATTENTIO