| Abstract Scope |
Tool life is a major factor in the cost of forgings, productivity, and part integrity. This paper will discuss a new methodology for enhancing the tool life of forging dies by manipulating the elastic strain field induced in the die and punches during forging, such that the retained contact stresses at the tool-workpiece interface are minimized or eliminated during punch ejection and release of the forging from the dies. The retained contact stress is attributed to the spring-back of the dies/punches. Finite element simulations of the proposed tooling architectures which facilitate the relaxation of elastic strain field in the die at the end of the forging stoke will be presented. To assess the viability of this technique, a number of forging geometries have been simulated including, CV joint, pinion shaft, hub spindle, and gearbox main shaft. The researchers are currently developing a laboratory scale tooling setup for experimental validation. |