Injection forging of solid asymmetric branched components

Abstract

Injection forging allows producing near-net or net-shape asymmetric branched components with geometries that are difficult or impossible to fabricate by means of conventional impression die forging. On the contrary to previous research work in the field that was mainly focused on proposing methodologies for shape classification, systematization of forming defects, definition of workability ranges and evaluation of the overall performance of finite element predictions against experiments, the aims and scope of this article are centred in material flow and forging load requirements that result from double-acting tool concepts with closing spring elements. The presentation includes details on the active tool parts that were utilized for producing solid branched components with different numbers of radial straight legs, on the mechanical characterization of the material and on the numerical simulation and experiments that were performed with selected test cases. Results and observations confirm that double-acting tool concept with closing spring elements is a flexible and efficient manufacturing process for producing injection forged components because it can eliminate the formability problems and defects that are commonly found in single-acting tool concepts and can avoid the need for employing multi-acting presses with counteracting punches.