Development of a CAD/CAM system for simulating closed forging process using finite‐element method

Abstract

Purpose

The purpose of this paper is to study the effect of the height and diameter of the dies as well as work‐piece dimensions, on stresses and strains on dies in the forging process. This helps in developing a better understanding of the effect of process parameters. As a result, the manufacturing task could be accomplished with minimal number of trials.

Design/methodology/approach

After determining the most influencing parameters on the forging process, the mechanical part is drawn, size of initial billet and shape of punch and die are also determined to build a finite‐element model to represent the process. Several outputs are taken as an indication for die wear and process performance. Finally, a computer numerical control (CNC) code to manufacture the selected die is generated.

Findings

It was found that when the die diameter increases, the effective stress decreases. On other hand, it was found that the work required to finish the forging process is highly affected by the dimensions of work‐piece. Therefore, it is possible to save power if work‐piece dimensions are adjusted.

Originality/value

This paper was meant to be a universal step or guide in developing a computer aided design/computer aided manufacturing (CAD/CAM) system to design, simulate, and manufacture molds for the forging process using a statistical method.

Citation

Al‐Omari, F., Al‐Jarrah, M., Omari, M. and Hayajneh, M. (2009), "Development of a CAD/CAM system for simulating closed forging process using finite‐element method", Engineering Computations, Vol. 26 No. 3, pp. 302-312. https://doi.org/10.1108/02644400910943635