Computer-Aided Die Design for the Hot Forging of an Automobile Generator Component

摘要

In the present study, the finite element software DEFORM with the Chinese graphic user interface was employed to analyze the hot forging process of manufacturing an automobile generator component, which is used as a holder of the coil. Since the coil holder bears a complex geometry with six claws extruded from the base, it cannot be produced by a single forging process, and in consequence, a preform is required to help the material flow in the subsequent forming process.The friction conditions and the material flow in different performing processes were discussed, and an optimum blank height and die design are then determined from different strokes of upsetting forging based on the finite element simulation results. In order to reduce the material cost, the closed-die forging process for producing a nearly net shape of the coil holder was also examined in the present study.According to the proposed closed-die design, the blank weight can be significantly reduced.The results of this study can be the reference resources for related academic research and also be used to develop related products for the factory manufacturing.