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Effect of shearing on production stability and die life in automatic multi-stage cold forging of an automobile wheel nut.

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Title: Effect of shearing on production stability and die life in automatic multi-stage cold forging of an automobile wheel nut.
Authors: Byun, Jong Bok1 (AUTHOR), Hamid, Nurhidayah Abd2 (AUTHOR), Cho, Gyu Seob3 (AUTHOR), Chung, Wan Jin4 (AUTHOR), Kang, Sung Muk5 (AUTHOR), Lee, Kwang Hee5 (AUTHOR), Joun, Man Soo1 (AUTHOR) msjoun@gnu.ac.kr
Source: International Journal of Advanced Manufacturing Technology. Mar2024, Vol. 131 Issue 1, p329-341. 13p.
Subjects: Automobile wheels, Stress concentration, Center of mass, Finite element method, Automobile safety
Abstract: In this study, the effects of earing in a sheared billet of S25C steel formed during rod shearing in an automatic multi-stage cold forging (AMSCF) process for an automobile wheel nut were experimentally and numerically investigated. Precision forging simulations with an emphasis on rod shearing were conducted using the implicit elastoplastic finite element method with a tetrahedral MINI-element scheme. AMSCF of an automobile wheel nut involves the use of a converging or near-conical die that shows a gradual reduction in its cross-sectional area. Our results showed that the shearing-induced earing plays the role of a pivot during balancing of the material inside the die cavity in the early stroke, before significant material contact. Earing formation resulted in a wobble motion of the material that accompanied the rigid-body motion. This ultimately led to a change in the center of mass of the material and unbalanced loading. Earing had a significant influence on the local high-cycle fatigue (HCF) fracture of die insets, especially in the cold forging of nut-like short products. The stress concentration on the die was attributed to asymmetric localized contact between the material and critical die corner, leading to changes in the mass center. Taken together, our results indicate that sheared billet characterization should account for earings with roll-overs and inclined surfaces to not only better predict the HCF life of die parts but also to optimize the forging outcome, particularly for safety products such as automobile wheel nuts. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Effect of shearing on production stability and die life in automatic multi-stage cold forging of an automobile wheel nut.
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  Data: <searchLink fieldCode="AR" term="%22Byun%2C+Jong+Bok%22">Byun, Jong Bok</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Hamid%2C+Nurhidayah+Abd%22">Hamid, Nurhidayah Abd</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Cho%2C+Gyu+Seob%22">Cho, Gyu Seob</searchLink><relatesTo>3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Chung%2C+Wan+Jin%22">Chung, Wan Jin</searchLink><relatesTo>4</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Kang%2C+Sung+Muk%22">Kang, Sung Muk</searchLink><relatesTo>5</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Lee%2C+Kwang+Hee%22">Lee, Kwang Hee</searchLink><relatesTo>5</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Joun%2C+Man+Soo%22">Joun, Man Soo</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> msjoun@gnu.ac.kr</i>
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  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Advanced+Manufacturing+Technology%22">International Journal of Advanced Manufacturing Technology</searchLink>. Mar2024, Vol. 131 Issue 1, p329-341. 13p.
– Name: Subject
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  Data: <searchLink fieldCode="DE" term="%22Automobile+wheels%22">Automobile wheels</searchLink><br /><searchLink fieldCode="DE" term="%22Stress+concentration%22">Stress concentration</searchLink><br /><searchLink fieldCode="DE" term="%22Center+of+mass%22">Center of mass</searchLink><br /><searchLink fieldCode="DE" term="%22Finite+element+method%22">Finite element method</searchLink><br /><searchLink fieldCode="DE" term="%22Automobile+safety%22">Automobile safety</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: In this study, the effects of earing in a sheared billet of S25C steel formed during rod shearing in an automatic multi-stage cold forging (AMSCF) process for an automobile wheel nut were experimentally and numerically investigated. Precision forging simulations with an emphasis on rod shearing were conducted using the implicit elastoplastic finite element method with a tetrahedral MINI-element scheme. AMSCF of an automobile wheel nut involves the use of a converging or near-conical die that shows a gradual reduction in its cross-sectional area. Our results showed that the shearing-induced earing plays the role of a pivot during balancing of the material inside the die cavity in the early stroke, before significant material contact. Earing formation resulted in a wobble motion of the material that accompanied the rigid-body motion. This ultimately led to a change in the center of mass of the material and unbalanced loading. Earing had a significant influence on the local high-cycle fatigue (HCF) fracture of die insets, especially in the cold forging of nut-like short products. The stress concentration on the die was attributed to asymmetric localized contact between the material and critical die corner, leading to changes in the mass center. Taken together, our results indicate that sheared billet characterization should account for earings with roll-overs and inclined surfaces to not only better predict the HCF life of die parts but also to optimize the forging outcome, particularly for safety products such as automobile wheel nuts. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1007/s00170-024-13017-9
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        Text: English
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      – SubjectFull: Automobile wheels
        Type: general
      – SubjectFull: Stress concentration
        Type: general
      – SubjectFull: Center of mass
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      – SubjectFull: Finite element method
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      – SubjectFull: Automobile safety
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      – TitleFull: Effect of shearing on production stability and die life in automatic multi-stage cold forging of an automobile wheel nut.
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            NameFull: Byun, Jong Bok
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            NameFull: Hamid, Nurhidayah Abd
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              M: 03
              Text: Mar2024
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              Y: 2024
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