International Journal of Engineering Trends and Technology (IJETT) – Volume 25 Number 4- July 2015
Forging simulation of Rocker arm using AFDEX software
Basavasagar1, Prof. Bharat S Kodli2
1M.TECH Scholar, Production Engineering, Department of Mechanical Engineering, PDA College of Engineering Gulbarga-585102, Karnataka-INDIA
2Professor, PG Coordinator, Production Engineering, Department of Mechanical Engineering, PDA College of Engineering Gulbarga-585102, Karnataka-INDIA
Abstract-.The purpose of this paper is to simulate the
closed die forging process, prediction of defect and
eliminating it to increase the product life. The task is to
simulate the Rocker arm using AFDEX software. To achieve
this objective CAD technology is combined with this process
simulation tools to enable modeling of rocker arm.The
structure of the rocker arm model was performed using
catia. Then forging simulation was performed using
AFDEX.
Keywords—: (AFDEX, CATIA, Rockerarm, stress)
II.SIMULATION
I. INTRODUCTION
Forging is defined as a metal working
process in which the useful shape of work piece is
obtained in solid state by compressive forces applied
through the use of dies and tools. Forging process is
accomplished by hammering or pressing the metal. It
is one of the oldest known metalworking processes
with its origin about some thousands of years back.
Traditionally, forging was performed by a smith using
hammer and anvil. Forging process produces parts of
superior mechanical properties with minimum waste
of material. In this process, the starting material has a
relatively simple geometry; this material is plastically
deformed in one or more operations into a product of
relatively complex configuration. Forging usually
requires relatively expensive tooling. Thus, the
process is economically attractive when a large
number of parts must be produced and/or when the
mechanical properties required in the finished product
can be obtained only by a forging process [1].
A forging die and a rectangular billet are modeled.
Die/billet interface contact friction, and die geometry
are varied to determine the effects of these variables
on material flow, stress, strain, and die force. An
attempt has been made to compute the load
requirement in the closed die forging process by using
MSC Super Forge during different stages of the
process [2].
In the previous days in research works a three
dimensional model using MSC/ DYNA is used to
closed die forging process. There are so many forging
simulation software like ansys, MSc ,super forge
etc,are used to stimulate a forging simulation of closed
die forging process but in these simulation of rocker
arm it can besimulated using AFDEX (Advisor as
friend for forging design expert ) software. The main
objective of these paper is to stimulate and analyzing
of closed die forging process [3].Forging is affected
by so many parameters such as work
piece,temperature, Friction between die andwork piece
ISSN: 2231-5381
and preformed billet. The 3D modeling of rocker arm
and die sets are performed by CATIA software, after
simulation and analysis of rocker arm performed by
AFDEX Software .These software has a capability of
identifying die filling, die contact and defect
formation etc. These software is also used to displays
a variety of parameters like strain rate, effective stress
and temperature, shear stress and final shape of
component.
Metal forming software (AFDEX-2012) will
be used in this project to design and simulate the metal
forging process. AFDEX is a general purpose metal
forming simulator, which can be applied not only to
conventional bulk metal forming processes including
forging, rolling, extrusion, and drawing, but also to
new creative bulk metal forming processes. AFDEX is
theoretically based on the rigid-thermoviscoplastic
finite element method. AFDEX can solve the metal
flow and heat transfer problems present in metal
forming and die structural analysis[4].
III. METHODOLOGY
In the present simulation of rocker arm using
AFDEX Software the below shown figure (1)
represents a flow chart of steps involved in simulation
according to flow chart simulation was performed .As
from flow chart initially we design a cad model of
rocker arm by given 2d drafting of rocker arm as
shown in figure . From the modeled rocker arm we
extract a suitable dies .According to the process,
materialcomposition, and properties given for the
product selecting a suitable die material. Finally
simulation is carried on AFDEX (Advisor as friend for
Forging Design Experts). If any defects are present,
changes are made in the dies. This leads to improved
results in the final product. The forging simulation
process will continue till we get product with least
defects.After successful simulation of rocker arm it
gives the least defects the rocker arm proceeds to the
mass production .Figures shows 2d drafting of rocker
arm considered for the analysis.. The work piece
material considered for the present analysis is AISI
1015 low-carbon steel. The chemical composition,
Mechanical properties of AISI 1015 low-carbon steel
are presented in Table 1 and Table 2.
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International Journal of Engineering Trends and Technology (IJETT) – Volume 25 Number 4- July 2015
Iron
99.13%
Carbon
0.13-0.18
Mn
0.30-0.60
Sulfur
0.0050
Phosphorus
0.040
Table: 2 Mechanical Properties OF AISI 1015 low
carbon steel
Tensile strength
385 Mpa
Yield strength
325 Mpa
Hardness rockwell
111
Density
7.87g/cc
Possions ratio
0.30
Forging temperature
900-1200
Fig: 1 Methodology.
Modeling in CATIA software
3D modeling software CATIA is used to model the
part, billet, and dies. Modeled components are shown
in below Figures.
Fig: 2 Part drawing of rocker arm .
Table :1 chemical properties of AISI 1015
STEEL.
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Fig: 3 3D Model of Rocker Arm
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International Journal of Engineering Trends and Technology (IJETT) – Volume 25 Number 4- July 2015
they are aligned manually. So care must be taken
while modeling dies and billet in CATIA.
As the given part has along Y axis, a rectangular
billet is used. Dies and billets are drawn in such a
manner that they are all aligned in the same axis. As
AFDEX accepts only .STL files, upper die, lower die
and billet are saved with .STL extension. All the files
of dies and billets with .STL extension are imported to
AFDEX database [4].
Fig:.4 : 3D Model of billet.
Table: 4 Forging Parameters.
Type of Forging
Hot Close-Die- Forging
(HCDF)
Work Piece Material
AISI 1015 (T=800012000C)
Die Material
Tool steel H 13
Press Type
Crank press
Friction Type
Graphite water hot Steel
Coefficient of Friction
0.7
Draft angle for die for
5-7 degree
Fig:5 3D Model of Die sets.
For the simulation of rocker arm in the catia software
some changes has to be made because the rocker arm
contains hole and some intricate portions these cannot
be forged because it has considered as machining
allowances and the forged part in the figure shown.
The forged part has to be added extra material in the
rocker arm and fillet and giving radius to the Rocker
arm
as
shown
in
figure.
Fig :6 Forging component involved all allowances .
ease of ejection
Temperature
900 - 1200
Stroke(-Y)
1.26 mm
IV.RESULT AND DISCUSSION
A. EFFECTIVE STRESS
Figure (7) shows effective stress of the rocker arm that
ensures the stress on the rocker arm while forging. In
figure 5 shows the billet is forged and the effective
stress is +1.323E+2 in 4.29 seconds with complete
flash around the billet that ensures the better strength
of Rocker arm. The different color highlights effective
stress at each intersection point of die contact with
billet and the global coordinates shows the values of
effective stress at different orientation of rocker arm
.In the analysis of rocker arm stress is always less than
the effective stress of material.
Even though AFDEX allows dies and billets to move
in X, Y and Z directions and rotate about X, Y and Z
directions it causes lot of problems in positioning, if
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International Journal of Engineering Trends and Technology (IJETT) – Volume 25 Number 4- July 2015
C . UNDER FILL.
Figure 9 shows the completely filled state of
material without any cavity on surface of billet, by this
it results better strength of the rocker arm.the below
figure shows9(a) billet is goimg to forged between
between upper and lower dies and figure 9(b) shows
forged rocker arm with completely cavity
filled9(A)and white colour indicates unfilled and green
colour indicates filled.
Fig: 7 Effective stress of forged rocker arm.
B.
TEMPERATURE
The temperature gradient is a physical quantity that
describes in which direction and at what rate
temperature changes most rapidly around the
particular location. Temperature is an objective
comparative measure of hot or cold. In Fig 8 it shows
the accurate temperature at each node of billet the
temperature changes on the rate of stroke and the die
contact on the work material. The different color
indicates the temperature changes on billet with
according to the change in stroke rate. The maximum
temperature changes are found at the die contact with
maximum stress on the billet at initial stages the flash
is less and the temperature is comparatively low. In fig
the rate of volume of billet is increased and the time of
stroke is also increased for this temperature gradient
on
billet
is
also
increased.
Fig :9(a) Billet is going to forged between upper
and lower dies.
Fig : 9(b) complete filled rocker arm .
D . HYDROSTATIC PRESUURE .
The figure(10) shows hydrostatic pressure of
completely filled forged rocker arm it forged between
upper and lower dies and it takes to complete a
forging is in 4.28 seconds and it shows 100.28 mpa as
shown in figure and hydrostatic presuure is varying in
its values according to stage wise.Rocker arm requires
100.28 mpa of hydrostatic pressure is require to forged
between between upper and lower dies and takes 4.28
seconds.
.Fig :8 temperature of rocker arm
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International Journal of Engineering Trends and Technology (IJETT) – Volume 25 Number 4- July 2015
Fig : 10Hydrostatic pressure of Rocker arm .
E .NODAL VELACITY.
Fig: 12 Load v/s Stroke diagram.
V.CONCLUSION
The below figure shows nodal velacity of rocker arm
as shown in below figure (11) and it was forged
brtween upper and lower dies and it takes time 4.28
seconds and nodal velacity is showing at the end of
forging of third stage at the rate of 2.56 mm/ s the
above nodal velacity shows the thesemuch of velacoty
is required to forge a rocker arm .
In the present work 3D model of rocker arm
component is simulated with AFDEX software to
study on forging simulation and overall functionality
of rocker arm. . Notable conclusions from this study
are
 By adopting the AFDEX simulation software, it is
possible to evaluate the flow analysis of material
at each stage. Therefore distribution was good and
no defect is observed.
 From the above results it can be concluded that
the die cavity is completely filled because stress is
less than the ultimate stress of material.
 The results reducing defects by complete filling
of material is achieved and has good strength of
workability.
REFERENCES
Fig : 11Nodal velacity of rocker am.
F . GRAPHS
The below figure (12) shows load v/s stroke its very
important in the simulation of rocker arm because the
rocker arm is forged between upper and lower dies. It
takes to forge a rocker arm is 4.28 seconds and it
takes load of 2.10 tons / s to forge a rocker arm .
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