Investigation of the cold forging operation steps’ effect on forming properties

Abstract

Cold forming is a manufacturing process that plastically deforms metal using dies. It allows for high speedproduction, little to no material waste compared to conventional machining, and creates a stronger end productdue to work hardening of the material. Cold working in forging process refers to the process of strengtheningsteel alloy by changing its shape without the use of heat. Subjecting the alloy to this mechanical stress causes apermanent change to the metal's crystalline structure, causing an increase in strength. At this time applieddeformation rate, velocity and die design of product effect the mechanical features, flow-orientation propertiesof sample and load requirements for forging process of rivets. In this study, it is aimed to investigate theoperation steps effect on formability characteristics of rivet produced by cold forming with the support of finiteelement method. Effective plastic strain, yield stress and forging force variations depending on die design wereobtained by simufact.forming simulation software. Simulations made with different die designs and physicalproduction results of these dies were compared. The effects of the number of forming operations and die cavityon the process were determined by performing material flow, hardness and structural analysis.