Automatic and precise simulation of multistage automatic cold-forging processes by combined analyses of two- and three-dimensional approaches

Abstract

We applied a combined two- and three-dimensional (2D and 3D, respectively) simulation techniques to analyze a sequence of multistage automatic cold-forging processes. After discussing recent forging simulation technology, a rigid-plastic finite element-based forging simulator known as AFDEX was introduced. A five-stage cold-forging sequence was selected as a representative example of multistage automatic forging processes because it has four axisymmetric forging stages followed by a non-axisymmetric forging stage and involves piercing and heading processes accompanying folding and overlapping. The importance of using a combined 2D and 3D simulation was illustrated in terms of the solution precision and accuracy, and computational efficiency.