Finite Element Simulation of Ball Joint under Hot Forging Process

Abstract

Abstract Nowadays, the finite element method (FEM) has been widely used to forecast the metal forming process and finding the parameter optimized. This work studied the use of FEM as a tool to design and process optimize a hot forging die for producing an automotive part named Ball Joint that part was made from carbon steel grade S45C. The objective of the study was to increase the efficiency of production and extend the life cycle of the machine by using load not exceeding the machine capability. To achieve this objective, the new parameters must produce workpieces without any defects. The defects regularly found in the forging workpieces are the thickness out of specification, the underfilling, and the crack. The parameter of the rougher and finisher process to studies and optimized that cover is the die gap and forming load. The die gap of 4, 3 and 2 millimeters and the forming load not exceeding 85% of machine capability were used in the hot forging simulation. From FEM simulation results, it was found that the die gap of 3 millimeters of the rougher and finisher process was the best to form workpieces without any defects, workpieces thickness within specification and the forming load not exceeding of 85%. In summary, the simulation and experimental results were compatible.