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Flashless forging of roller bearings in a single stroke enabled by numerical simulation and validated experimentally.

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Title: Flashless forging of roller bearings in a single stroke enabled by numerical simulation and validated experimentally.
Authors: Shaker, Ahmed G1 (AUTHOR), Amer, Mazen1 (AUTHOR), Abdellatif, May1 (AUTHOR), Mohsen, Omar1 (AUTHOR), Elkaseer, Ahmed1,2 (AUTHOR) ahmed.elkaseer@bue.edu.eg, El-Mahallawi, Iman1,3 (AUTHOR) ielmahallawi@bue.edu.eg
Source: International Journal of Advanced Manufacturing Technology. Jul2026, Vol. 145 Issue 1/2, p1015-1035. 21p.
Subjects: Forging (Manufacturing process), Computer simulation, Finite element method, Model validation, Roller bearings, Waste minimization
Abstract: Conventional production of bearing races relies on multi-stage forging or machining of individual rings, leading to high material waste, flash formation, and die wear. This study introduces a novel flashless dual-ring forging process capable of forming both inner and outer bearing races in a single stroke. The process was designed and optimized through finite-element-based numerical simulation, benchmarked against validated literature data to ensure model fidelity. A comprehensive parametric study was then conducted to evaluate the coupled effects of preform geometry, circular web thickness, and location on strain distribution, press load, and cavity filling. The optimized configuration achieved full cavity filling without laps or folding defects, while reducing material waste from 34% in conventional routes to 15%. Simulated press forces and die stress distributions showed strong agreement with experimental forging trials, confirming the predictive accuracy of the developed model. Experimental validation using a custom-manufactured die and 100-ton press demonstrated excellent conformity between the numerically predicted and actual cross-sections of the forged parts. The proposed single-stroke dual-ring die concept represents the first experimentally verified framework for flashless bearing race forging, offering up to 40% reduction in waste, lower energy consumption, and extended die life. The findings establish a transferable methodology for sustainable and high-precision production of concentric ring components in industrial applications. [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.)
Database: Engineering Source
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Header DbId: egs
DbLabel: Engineering Source
An: 195542880
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
PreciseRelevancyScore: 0
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Items – Name: Title
  Label: Title
  Group: Ti
  Data: Flashless forging of roller bearings in a single stroke enabled by numerical simulation and validated experimentally.
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  Data: <searchLink fieldCode="AR" term="%22Shaker%2C+Ahmed+G%22">Shaker, Ahmed G</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Amer%2C+Mazen%22">Amer, Mazen</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Abdellatif%2C+May%22">Abdellatif, May</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Mohsen%2C+Omar%22">Mohsen, Omar</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Elkaseer%2C+Ahmed%22">Elkaseer, Ahmed</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<i> ahmed.elkaseer@bue.edu.eg</i><br /><searchLink fieldCode="AR" term="%22El-Mahallawi%2C+Iman%22">El-Mahallawi, Iman</searchLink><relatesTo>1,3</relatesTo> (AUTHOR)<i> ielmahallawi@bue.edu.eg</i>
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  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Advanced+Manufacturing+Technology%22">International Journal of Advanced Manufacturing Technology</searchLink>. Jul2026, Vol. 145 Issue 1/2, p1015-1035. 21p.
– Name: Subject
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  Data: <searchLink fieldCode="DE" term="%22Forging+%28Manufacturing+process%29%22">Forging (Manufacturing process)</searchLink><br /><searchLink fieldCode="DE" term="%22Computer+simulation%22">Computer simulation</searchLink><br /><searchLink fieldCode="DE" term="%22Finite+element+method%22">Finite element method</searchLink><br /><searchLink fieldCode="DE" term="%22Model+validation%22">Model validation</searchLink><br /><searchLink fieldCode="DE" term="%22Roller+bearings%22">Roller bearings</searchLink><br /><searchLink fieldCode="DE" term="%22Waste+minimization%22">Waste minimization</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Conventional production of bearing races relies on multi-stage forging or machining of individual rings, leading to high material waste, flash formation, and die wear. This study introduces a novel flashless dual-ring forging process capable of forming both inner and outer bearing races in a single stroke. The process was designed and optimized through finite-element-based numerical simulation, benchmarked against validated literature data to ensure model fidelity. A comprehensive parametric study was then conducted to evaluate the coupled effects of preform geometry, circular web thickness, and location on strain distribution, press load, and cavity filling. The optimized configuration achieved full cavity filling without laps or folding defects, while reducing material waste from 34% in conventional routes to 15%. Simulated press forces and die stress distributions showed strong agreement with experimental forging trials, confirming the predictive accuracy of the developed model. Experimental validation using a custom-manufactured die and 100-ton press demonstrated excellent conformity between the numerically predicted and actual cross-sections of the forged parts. The proposed single-stroke dual-ring die concept represents the first experimentally verified framework for flashless bearing race forging, offering up to 40% reduction in waste, lower energy consumption, and extended die life. The findings establish a transferable methodology for sustainable and high-precision production of concentric ring components in industrial applications. [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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RecordInfo BibRecord:
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    Identifiers:
      – Type: doi
        Value: 10.1007/s00170-026-18347-4
    Languages:
      – Code: eng
        Text: English
    PhysicalDescription:
      Pagination:
        PageCount: 21
        StartPage: 1015
    Subjects:
      – SubjectFull: Forging (Manufacturing process)
        Type: general
      – SubjectFull: Computer simulation
        Type: general
      – SubjectFull: Finite element method
        Type: general
      – SubjectFull: Model validation
        Type: general
      – SubjectFull: Roller bearings
        Type: general
      – SubjectFull: Waste minimization
        Type: general
    Titles:
      – TitleFull: Flashless forging of roller bearings in a single stroke enabled by numerical simulation and validated experimentally.
        Type: main
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          Name:
            NameFull: Shaker, Ahmed G
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            NameFull: Amer, Mazen
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            NameFull: Abdellatif, May
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            NameFull: Mohsen, Omar
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            NameFull: Elkaseer, Ahmed
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            NameFull: El-Mahallawi, Iman
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            – D: 01
              M: 07
              Text: Jul2026
              Type: published
              Y: 2026
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              Value: 145
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              Value: 1/2
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            – TitleFull: International Journal of Advanced Manufacturing Technology
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