Die stress and friction behaviour analysis in bolt farming

Aygen, Mert
In cold forming operations, tool geometry has a direct influence on the product quality, forming force, load acting on dies and tool life. Finite element method provides a means to analyse these parameters to predict forming defects and die failures. In this study, shrink fitting the components of a bolt forming die is modelled and the finite element results are compared with the analytical solutions and experiments. In order to perform die stress analyses, deformable die models are implemented in the forging simulations. Furthermore, effect of using rigid and deformable dies on the stress distributions in the tools, forming force and product dimensions are examined. Some applications of tool geometry improvements and optimization of prestressing are presented in the case studies. In the second part of the study, the appropriate friction model for the cold forming operation of bolts is investigated. For this purpose, ring compression and forward rod extrusion tests are conducted. Dimensional variations and deformation forces are compared with the finite element simulations performed for different friction models and constants. The results of shrink fit analyses of die prestressing are in good agreement with the elasticity formulations and real applications. In the studied bolt production cases, after improving the die stress distributions by using FE simulations, longer tool lives are achieved. Finally, for more accurate results, Coulomb friction model is determined as an appropiate model for bolt forming analyses.


Friction analysis in cold forging
Cora, Ömer Necati; Akkök, Metin; Department of Mechanical Engineering (2004)
Friction is one of the important parameters in metal forming processes since it affects metal flow in the die, forming load, strain distribution, tool and die life, surface quality of the product etc. The range of coefficient of friction in different metal forming applications is not well known and the factors affecting variation are ambiguous. Commercially available FEA packages input the coefficient of friction as constant among the whole process which is not a realistic approach. In this study, utility o...
Finite element analysis and manufacturing of fin connector rod by hot forging process
Şerbetçi, Barbaros; Darendeliler, Haluk; Department of Mechanical Engineering (2009)
Forging operation is one of the most commonly used manufacturing techniques in defense industry. The products of forging operation have higher material strength when comparing to traditional manufacturing operations. Especially, for the mass production, it is a beneficial method considering metal and cost saving. The commonly used part named Fin Connector Rod in defense industry requires high material strength due to working conditions. In this thesis, manufacturing of this part by hot forging operation is ...
Exact solution of rotating FGM shaft problem in the elastoplastic state of stress
Akis, Tolga; Eraslan, Ahmet Nedim (Springer Science and Business Media LLC, 2007-10-01)
Plane strain analytical solutions to estimate purely elastic, partially plastic and fully plastic deformation behavior of rotating functionally graded (FGM) hollow shafts are presented. The modulus of elasticity of the shaft material is assumed to vary nonlinearly in the radial direction. Tresca's yield criterion and its associated flow rule are used to formulate three different plastic regions for an ideal plastic material. By considerina different material compositions as well as a wide range of bore radi...
Development of a shell finite element for large deformation analysis of laminated composites
Yıldız, Tuba; Darendeliler, Haluk; Department of Mechanical Engineering (2008)
The objective of the present work is to investigate the behavior of laminated fiber -reinforced polymer matrix composite shell structures under bending load with the help of a modified finite element computer code which was previously developed for the analysis of pseudo-layered single material shells. The laminates are assumed to be orthotropic and the formulation is adapted to first order shear deformation theory. The aim is to determine the large deformation characteristics numerically, and to predict th...
Transient dynamic response of viscoelastic cylinders enclosed in filament wound cylindrical composites
Şen, Özge; Turhan, Doğan; Department of Engineering Sciences (2005)
In this study, transient dynamic response of viscoelastic cylinders enclosed in filament wound cylindrical composites is investigated. Thermal effects, in addition to mechanical effects, are taken into consideration. A generalized thermoelasticity theory which incorporates the temperature rate among the constitutive variables and is referred to as temperature-rate dependent thermoelasticity theory is employed. This theory predicts finite heat propagation speeds. The body considered in this thesis consists o...
Citation Formats
M. Aygen, “Die stress and friction behaviour analysis in bolt farming,” M.S. - Master of Science, Middle East Technical University, 2006.