Application of Numerical Simulation and Physical Modeling for Verifying a Cold Forging Process for Rotary Sleeves

This paper presents the modeling of a cold forging process for a rotary sleeve. The process of forging a EN 42CrMo4 steel part was first modeled numerically by the finite element method using simulation software DEFORM 3D ver. 11.0. After that, the developed forging process was verified by experimental tests carried out in laboratory conditions with the use of 1:2 scale tools and a material model of aluminum alloy EN AW-6060. Finite element method (FEM) results demonstrated that rotary sleeves could be formed from tubes by cold forging. Results of the experimental tests showed, however, that the material inside the hole of the work piece might not adhere to the surface of the sizing pin. Distributions of strain and stress during the forging process are determined. Geometrical parameters of forged parts obtained in experimental tests are compliant with the dimensions of forged parts simulated by FEM. In addition, experimental forces of the forging process show a high agreement with the forces obtained in FEM simulations.