Numerical Simulation of Hot Forging Process of KIA Car Brake’s Output Shaft

محورهای موضوعی : metal forming

saeid Hashemian ¹ , Peyman Mashhadi Keshtiban ² , Abuzar Es'haghi Oskui ³

1 - Faculty of Mechanical Engineering, Urmia University of Technology, Urmia, Iran
2 - Faculty of Mechanical Engineering, Urmia University of Technology, Urmia, Iran
3 - Department of Mechanical Engineering, College of Engineering, University of Tehran, Tehran, Iran

تاریخ دریافت : 1400/03/25 تاریخ پذیرش : 1400/07/13 تاریخ انتشار : 1400/12/10

کلید واژه: Friction Coefficient, temperature, Hot forging, Loading Rate, Finite Element Simulation,

چکیده مقاله :

The present study investigates the production process by closed die forging method of one of the sensitive and safe parts of KIA car brake, which is affected by various mechanical and thermal stresses in its operating conditions; therefore, in the present research, the application of this forming method in the Iranian automotive industry has been discussed. In this study, an attempt was made using finite element analysis in ABAQUS software to determine the maximum force required for forging this part. In addition, the influence of various parameters such as the temperature of the part during the forming process, the coefficient of friction between the part and the die, as well as the strain rate have been investigated. The results indicated that the friction coefficient has a significant effect on the maximum required force, and the maximum values of the load increase with increasing the friction coefficient; but the remarkable result is that the effect of this coefficient is negligible from a value onwards. This point is consistent with the observations in practice. Besides, a strong dependence of the results on the loading speed was observed, and the required force has increased with increasing loading speed for reasons such as the strain hardening phenomenon. Also, the force required for forging has decreased with increasing the temperature, which is due to reduced material strength. This reduction from 900°C to 1000°C is less than 2%, while it is approximately 40% from 1000°C to 1100°C, which is consistent with the experimental reports.

منابع و مأخذ:

• Grass, H., Krempaszky, C., and Werner, E., 3-D Fem-Simulation of Hot Forming Processes for The Production of a Connecting Rod, Computational Materials Science, Vol. 36, No. 4, 2006, pp. 480-489.


• Vazquez, V., Altan, T., Die Design for Flashless Forging of Complex Parts, Journal of Materials Processing Technology, Vol. 98, No. 1, 2000, pp. 81-89.


• Lv, C., Zhang, L.,Mu, Z., Tai, Q., and Zheng, Q., 3D Fem Simulation of The Multi-Stage Forging Process of a Gas Turbine Compressor Blade, Journal of Materials Processing Technology, Vol. 198, No. 1-3, 2008, pp. 463-470.


• Alimirzaloo, V., Biglari, F. R., Sadeghi, M. H., Keshtiban, P. M., and Sehat, H. R., A Novel Method for Preform Die Design in Forging Process of an Airfoil Blade Based On Lagrange Interpolation and Meta-Heuristic Algorithm, The International Journal of Advanced Manufacturing Technology, Vol. 102, No. 9, 2019, pp. 4031-4045.


• Taghavi, V., Alimirzaloo, V., Solimanpur, M., Mashhadi Keshtiban, P., and Sheydaei Govarchin Ghaleh, S., An Investigation of The Effective Factors in The Shape Rolling Process of a Compressor Blade, Iranian Journal of Materials Forming, Vol. 7, No. 2, 2020, pp. 16-25.


• Yuli, L., Kun, D., Mei, Z., He, Y., and Fuwei, Z., Physical Modeling of Blade Forging, Journal of Materials Processing Technology, Vol. 99, No. 1-3, 2000, pp. 141-144.


• Zhang, Y., Shan, D., and Xu, F., Flow Lines Control of Disk Structure with Complex Shape in Isothermal Precision Forging, Journal of Materials Processing Technology, Vol. 209, No. 2, 2009, pp. 745-753.


• Ou, H., Wang, P., Lu, B., and Long, H., Finite Element Modelling and Optimisation of Net-Shape Metal Forming Processes with Uncertainties, Computers & Structures, Vol. 90, No. 2012, pp. 13-27.


• Sadeghi, M., Khosravi, A., Parametric Design, Mold Design and Manufacture of Precision Forging Gear Pinion 405 Using cad/cam, Journal of Modares Mechanical Engineering, Vol. 8, No. 2008, pp.


• Parseh, Y., Sadeghi, M., Numerical Simulation and Physical Modeling to Produce a Piece of Walnut Plous by Using a Precise Forging Process, Journal of Modares Mechanical Engineering, Vol. 8, No. 2010.


• Yazdi, M. S., Bagheri, G. S., and Tahmasebi, M., Finite Volume Analysis and Neural Network Modeling of Wear During Hot Forging of a Steel Splined Hub, Arabian Journal for Science and Engineering, Vol. 37, No. 3, 2012, pp. 821-829.


• Narayan, S., Rajeshkannan, A., Hardness, Tensile and Impact Behaviour of Hot Forged Aluminium Metal Matrix Composites, Journal of Materials Research and Technology, Vol. 6, No. 3, 2017, pp. 213-219.


• Sweet, G., Williams, B., Taylor, A., Hexemer, R., Donaldson, I., and Bishop, D., A Microstructural and Mechanical Property Investigation of a Hot Upset Forged 2xxx Series Aluminum Powder Metallurgy Alloy Reinforced with Aln, Journal of Materials Processing Technology, Vol. 284, No. 2020, pp. 116742.


• Dareini, M., Jabbari, A., and Sedighi, M., Effect of Nano-Sized Al2o3 Reinforcing Particles on Uniaxial and High Cycle Fatigue Behaviors of Hot-Forged Az31b Magnesium Alloy, Transactions of Nonferrous Metals Society of China, Vol. 30, No. 5, 2020, pp. 1249-1266.


• Choi, Y. J., Lee, S. K., Lee, I. K., Hwang, S. K., Yoon, J. C., Choi, C. Y., Lee, Y. S., and Jeong, M. S., Hot Forging Process Design of Sprocket Wheel and Environmental Effect Analysis, Journal of Mechanical Science and Technology, Vol. 32, No. 5, 2018, pp. 2219-2225.


• Zhuang, W., Hua, L., Wang, X., Liu, Y., Dong, L., and Dai, H., The Influences of Process Parameters On the Preliminary Roll-Forging Process of The Aisi-1045 Automobile Front Axle Beam, Journal of Mechanical Science and Technology, Vol. 30, No. 2, 2016, pp. 837-846.


• Dieter, G. E., Bacon, D. J., Mechanical Metallurgy, ed., McGraw-Hill New York, 1986.


• Valberg, H. S., Applied Metal Forming: Including Fem Analysis, ed., Cambridge University Press, 2010.


• Mashhadi Keshtiban, P., Taher, A., and Mashhadi Keshtiban, M., Practical Study and Finite Element Simulation of Production Process of The Bush of Gearbox of Mercedes-Benz 10-Wheel Truck by Closed Die Forging, Journal of Computational Applied Mechanics, Vol. No. 2020.