Process analysis of multistage forging by using finite element method

Much progress in forging technology including low production cost and fast production has allowed an intensive use of forging. Manufacturing companies have especially focused on producing a complex shaped part with a tight dimensional tolerance. Traditional warm and cold forging methods have their own limitations to produce such a complex shaped part; warm forging requires complex system with relatively higher manufacturing cost, while cold forging is not applicable to materials with limited formability. Therefore, multistage forging may be advantageous to produce complex shaped parts. In order to build a multistage forging system, it is necessary to characterize mechanical properties in response to system design parameters such as temperature, forging speed and reduction. For the analysis of formability of multistage forging process, finite element method (FEM) has been used for the process analysis. As a model case, a constant velocity (CV) joint forging process is analyzed by FEM, since CV joint has a complex shape and also its required dimensional tolerances are very tight. A systematic approach to process analysis is established using the FEM for the multistage forging of the CV joint outer race.