Analysis of the Industrial Process of Producing a Hub Forging Used in Motorcar Power Transmission Systems—A Case Study

Abstract

The article refers to an analysis of the multi-operation process of manufacturing a hub type forging used to transmit power in motorcar gear boxes, by way of die forging on a crank press. The investigations were performed in order to improve the currently realized production technology, mainly with the use of numerical simulations. Through the determination of the key parameters/quantities during forging, which are difficult to determine directly during the industrial process, an in-depth and complex analysis was performed by way of FE (Finite Element) modelling. A thermomechanical model of producing a hub forging with deformable tools was developed with the use of the Qform 9.0.9 software. For the elaboration and construction of the forging tool CAD (Computer Aided Design) models, the Catia V5R20 program was applied. The results of the performed numerical modelling made it possible to determine the material flow and the properness of the filling of impressions, as well as the temperature field distributions and plastic deformations in the forging; it was also possible to detect the forging defects often observed in the industrial process. On this basis, the changes in the process were determined, which enabled an improvement of the presently realized technology and the obtaining of proper forgings, both in respect of quality and dimensions and shape.