The Numerical Simulation Of Closed-die Forging Process For A Forging Used In Manual Electric Drills

With the competition of international manufacture, the forming technology of economizing energy, accuracy and high efficiency becomes one of the current research trends of metal plastic forming field. The precision forging process replaces the traditional manufacturing process, which can economize energy and material, enhance the efficiency, improve the quality of products and reduce the cost. The hardware is a very important part of manual electric drill,which plays a role as connecting the aiguille and the main body of the manual electric drill. At present, the traditional manufacturing technique of this part as the turning method, has many disadvantages, such as inefficient use of material,high production cost,bad using performance. With the improvement of market requirements for high quality and low cost, the traditional manufacturing technique will not meet the demands of companies. The machining technology of this hardware should be reformed.With the fast development of computer hard and soft wares, finite element method(FEM) and computer graphics, the computer aided engineering technology based on numerical simulation is used widely in metal plastic forming field. The simulation of metal forming processes can be realized on the computer. And this paper is based on these technologies,with which all the 3D models and numerical simulations in this paper are carried out.Firstly, this paper analyzes the forming process of the hardware of manual electric drill with the method of finite element numerical simulation .The 3D FEM model of the precision forging process of this hardware of manual electric drill is established. And three different methods of forming process are designed,after comparing their primary performance,the stand-closed die forging process is selected to be optimized,which is the only one that can shape up well with just one step.Then the input data for the simulation,such as surface meshes of workpiece,solution step control,fraction modulus,up-die's speed and temperature are discussed according to the FEM simulation results. And the forming laws,the distribution of the stress and strain of the workpiece are obtained. The conclusions offer a steady support to obtain reliable numerical results.Thirdly, the parameters of the forging itself are discussed,which include the flash thickness.the flash width,fillet radius and the draft angle. On the basis of analyzing the metal forming performance,flow rules.initial effective stress and strain,and the load-stroke curve,reasonable datas of them are obtained. Besides,the final data of flash thickness and width are compared to the theoretic formula. The die design is optimized and the utility ratio of material is improved.