A forging method for reducing process steps in the forming of automotive fasteners. (March 2018)

• Record Type: Journal Article
• Authors: Chen, Senyong; Qin, Yi; Chen, J.G.; Choy, Chee-Mun
• Is Part Of: International journal of mechanical sciences. Volume 137(2018)
• Page Start: 1
• Page End: 14
• Publication Date: 2018-03
• Subjects: Automotive fasteners -- Multisteps forging -- Injection forging -- FE analysis -- Forming experiment; Mechanical engineering -- Periodicals; Génie mécanique -- Périodiques; Mechanical engineering; Maschinenbau; Mechanik; Zeitschrift; Periodicals; 621.05
• DOI: 10.1016/j.ijmecsci.2017.12.045
• Languages: English
• ISSNs: 0020-7403

Abstract

Highlights: Reducing process steps in automotive fastener production. Using injection forging to achieve combined material flows. Examining forming force/energy requirements, material properties and forming quality. Concluding the feasibility of injection forging for the fasteners production for process step reduction. Recommending process deployment and tool-design considerations. Abstract: The automotive component manufacturing sector is experiencing fierce competitions. To enable improvements in production efficiency, the authors introduced single step injection forging as an alternative to conventional multisteps forging processes for manufacturing automobile fasteners, being enabled by a dedicated tool-design to achieve combined material-flows and hence, a complex component-form. To assist in this, a feasibility study was conducted, including comparisons of conventional multisteps forging with injection forging, through FE simulations, experimental validation of the injection forging process, as well as detailed examinations of the quality of the parts formed. The simulations were focused mainly on the forming of a wheel bolt. Axi-symmetric models were developed to analyse forging force and energy requirements, resulting forming-errors and tool stresses for each process. Injection forging tests were carried out in a factory environment with the aim of verifying the FE results and of confirming process and tool-design feasibility. Based on the results from these studies, the feasibility of replacing multisteps forging with injection forging was confirmed. It was established that injection forging may demand higher a forming force in its single step but it would consume less energy. Also, there is less chance of developing flow faults during injection forging, which is critical for the forming of the automotive fasteners. Nevertheless, due to the complex material-flow in injection forging and large die-deflections, a dedicated tool-design for compensating for forming-errors and for enhancing tool-life has to be enabled for the forging production applications. Graphical abstract: