Advancements in forging processes
Computer Aided Engineering (CAE) in Cold Forging Process
全球竞争需要冷锻行业利用实用和经过验证的计算机辅助设计（CAD），计算机辅助制造（CAM）和计算机辅助工程（CAE）技术，用于快速，经济高效的工艺设计和模具制造。这导致更高的准确性，生产质量，拒绝不那么少。目前，有限元方法（FEM）模拟软件已成为锻造工艺设计的组成部分，以分析和优化金属流动并在进行锻造试验之前进行模具应力分析。
FEM模型中的输入变量
- The accuracy of FEM process simulation depends heavily on the accuracy of the input data it should be as near as realistic values, like properties in real world are not constant, they vary depending on other parameters, namely,
- a）在界面处的温度，应变，应变率和微观结构，b）摩擦特性的流动应力。
微F.orging生物医学刀片和工具
由于缩小规模趋势，现在可以为电子和医疗保健应用生产尺寸小于1毫米的冷锻造物品。3D蚀刻和其他金属移除程序现在用于制作这些部件。微铸具有大量生产净形状/近净形状的微量组分的大量。但是，对以下方面的完全了解是用于成本效益和竞争性的：a）尺度效应/微泡性，b）微观结构对工艺的影响，c）工具的相对刚度，d）过程控制和能力。
精确冷F.orging动力转向小齿轮和内部比赛
带螺旋齿，螺旋齿轮和内部比赛的动力转向小齿轮难以锻造净形状。然而，通过减少许多试验和提高组件质量，刀具寿命和锻件的几何复杂性，在过程开发中使用商业3D有限元件软件的生产成本基本降低。图3表示FEM在设计和开发中的使用，用于制造所示小齿轮的螺旋挤出过程。使用FEM模拟和因此设计的优点是......
- 获得更好的驱动感。
- 容易地产生牙齿曲线。
- 为模具和过程以及热处理创造迭代设计方法。
Figure 4 indicates the simulation of cold forging of the inner race, which is a element of the constant velocity joint assembly. The raw material is a forged round bar. Thus, precise control of the billet volume has to be ensured. This can be validated with help of FEM simulations in addition to the metal flow and die stress analysis. The advantages of simulating following process are…
- 在凹槽上获得的网状，从而消除了整理阶段中使用的昂贵磨削过程。
- Establish an iterative technique for die and process design as well as heat treatment.
- 在不使用特殊新闻的情况下安全锻造准确性。
多动作精密成型压力机
Multi-action forming is a good way to get a net shape out of a part with a lot of properties. Several press and die companies have recently focused on developing novel concepts in this area. More than one pressure source is used to operate the dies and slide in multi-action forming. During one stroke, the dies also perform many relative moves. A multi-action press for forming helical gears is shown in Figure 5a. This hydraulically operated press has 5 cylinders; one for driving the slide, two cylinders in the slide and two in the bed. Figures 5 shows the construction of a die for forming the helical gear
Hollow forgings by hydroforming process
液压成形是一种金属制造和形成技术，允许钢，不锈钢，铜，铝和黄铜等金属。这是一种经济型和专用的模具模型，其使用高压液形成金属。
Hydroforming is generally divided into two categories: sheet hydroforming and tube hydroforming. One die and a sheet of metal are used in sheet hydroforming; the blank sheet is forced into the die by high-pressure water on one side, forming the required shape. The expansion of metal tubes into a shape using two die halves that contain the raw tube is known as tube hydroforming.
The earlier method of stamping two part halves and welding them together has been replaced by hydroforming. It’s also utilised to build parts more efficiently by obviating the need for welding and to create intricate shapes and contours. Seamless bonding, enhanced part strength, and the ability to preserve high-quality surfaces for finishing reasons are just a few of the production advantages of parts made this way.
Hydroformed parts are lighter, have a cheaper cost per unit, and have a higher stiffness to weight ratio than standard metal stamped and welded parts. The methods can also be used to produce components in a single stage, saving time, money, and materials.
Hollow rotor shafts for EVs using radial forging
The radial forging tendencies are well-defined. Electric motor rotor shafts are currently available on the automotive market. Their standard design appears to be based on radial forging technology’s capabilities. A semi-hot forging method is the finest option. Figure 7 shows images of typical EV rotor shafts. As the number of electric vehicles grows, radial forging will become a more important part of the manufacturing process.
Hybrid forgingfor crown-shape gear
用于汽车工业的高品质齿轮传统上加工成锻造预制件，浪费材料和能量。该焦点现在已经转移到齿轮的典型锻造。然而，这可能需要高锻造载荷，因此大压尺寸。由于其牙齿的定位，一些齿轮可能难以构建。因此，齿轮的锻造不是一个简单的任务。
Rotary forging is a viable option in this situation. It minimises machining by using gradual deformation locally with the material to get near net shape results. Because of the reduced contact, the forging load can be reduced significantly, resulting in smaller presses. As an example, this technique exhibits the evolution of the rotary forging process in conjunction with conventional forging to produce crown gear teeth. The hot conventional forging is first shown, which is based on a closed die forging procedure to generate the rotating preform. The forged teeth are then achieved by a semi-finished technique known as rotary forging.
References
- Liewald等人。，“锻造技术的新发展”, 2015 INVENTUM GmbH
- Taylan Altan博士，“State of Cold forging Technology in Global Competition“俄亥俄州州立大学
- Sonia Varela, Oscar Valbuena, “通过旋转锻造和常规方法的组合节省材料：用于网状齿轮的混合锻造”, AIP Conference 2019
- 用径向锻造来塑造未来的创新，Forge Mag.
- 管液压成型步进过程那American Hydroformers
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