New concepts in die design — physical and computer modeling applications

The application of Computer Aided Engineering and physical modeling techniques in forging R & D continues to increase. In using tools such as Finite Element Modeling and experiments with model materials, the forging tool designer can decrease costs by improving achievable tolerances, increasing tool life, predicting and preventing flow defects, and predicting part properties. At the Engineering Research Center for Net Shape Manufacturing, Design Environment for Forming (DEFORM) and DEFORM 3D, and a multiple action press for physical modeling are tools available for forging research and for educational purposes. This paper summarizes the results of industrially relevant “work-in-progress” research with numerical and physical modeling systems. Current projects include: a tool design for the forging of a cross groove inner race for a constant velocity joint, and the design of a tooling to forge a connecting rod without flash.