PhD AWARDED 1992

PhD Studies at Dublin City University

Metal flow simulation and design of dies for closed die forging

Welcome to my Academic Digital Portfolio. I am Dr. Faek Sido Diko, and I am pleased to introduce my Doctor of Philosophy (Ph.D.) research titled "Metal Flow Simulation and Design of Dies for Closed Die Forging". This thesis was submitted in fulfillment of my Ph.D. degree in Mechanical & Manufacturing Engineering at Dublin City University in September 1992, under the supervision of Prof. Saleem Hashmi.

Research Motivation and Scope

My research addresses the complex process of metal forming, particularly focusing on closed die forging. Traditional forging design relied heavily on empirical methods, leading to inefficiencies and errors. My research integrates CAD systems, finite element analysis (FEA), and die design methodologies to improve the accuracy and efficiency of closed die forging design.

The study proposes an interactive CAD system that enables drawing die geometries, simulating metal flow during forging, and analyzing die behavior under forming conditions. This integrated system provides a powerful platform for improving manufacturing precision and reducing costly trial-and-error processes.

Key Contributions and Innovations

The major contributions of my Ph.D. research include:

CAD Customization for Forging Design:
- Developed customized CAD routines using AutoLISP to automate drafting tasks such as machining allowance, draft angles, and corner radii adjustments.
Finite Element Analysis (FEA):
- Developed a rigid-plastic/viscoplastic finite element program to simulate metal flow during the forging process, enhancing predictive accuracy for deformation and stress distribution.
Mesh Generation and Rezoning Algorithms:
- Designed an automatic mesh generation system that adapts dynamically to deformation patterns, ensuring better simulation precision and overcoming computational challenges in large deformation scenarios.
Die Analysis with Elastic-Plastic FEM:
- Implemented an elastic-plastic finite element model to analyze die behavior, ensuring durability under forging conditions.
Practical Application and Experimental Validation:
- The developed system was tested on multiple forging examples, including plane-strain and axisymmetric conditions, with results closely aligning with experimental observations.

Practical Application

My Ph.D. research has been instrumental in improving forging design practices. The system effectively designs dies for complex mechanical components while minimizing material waste and ensuring die longevity. The developed framework can be expanded to include:

3D solid modeling for advanced die designs.
Temperature simulations to predict heat-induced deformation.
Automated CNC programming for die manufacturing.

Research Impact and Future Directions

This research has paved the way for smarter forging solutions in manufacturing. The integration of CAD systems and FEA offers a robust solution for improving design accuracy, enhancing production efficiency, and reducing manufacturing costs. I welcome students, researchers, and industry professionals interested in expanding on this work or collaborating in related research areas.

Collaboration Opportunities

If you are interested in conducting research in metal forming, forging design, or finite element simulation, I encourage you to explore my research further. The complete thesis is available for detailed study at the following link: Metal Flow Simulation and Design of Dies for Closed Die Forging.

For inquiries, discussions, or collaborative opportunities, please feel free to contact me.

Click To Access This Work On The Dublin City University Repository

PhD Thesis Details:

TITLE: Metal Flow Simulation and Design of Dies for Closed Die Forging

AUTHOR: Faek Sido Diko

ISSN:

AWARDING BODY: Dublin City University

CURRENT INSTITUTION: University of Duhok

DATE AWARDED: 1992

Full Text Link: [PLEASE CLICK TO VIEW THE FULL TEXT OF MY M.Sc.]

SUPERVISOR: Prof. Dr. M. S. Saleem Hashmi

SPONSOR: Dublin City University and The Scientific Studies and Research Center, DAMASCUS - SYRIA

QUALIFICATION NAME: Doctor of Philosophy of Engineering in Mechanical Engineering

QUALIFICATION LEVEL: PhD

LANGUAGE OF THE THESIS: English

Citation to this work:

Diko, F. (1992). Metal Flow Simulation and Design of Dies for Closed Die Forging [Doctoral dissertation, Dublin City University]. DORAS Institutional Repository. https://doras.dcu.ie/18504/

Abstract:

The application of computer aided design and computer aided manufacturing (CAD/CAM) technique to forming is gaining popularity as the resulting productivity improvements are becoming more and more apparent. Most users are using CAD/CAM and finite element packages as stand-alone packages, where the integration among these packages in most cases is difficult due to the differences in the layout format of each one.

Finite element packages usually have then own pie- and post processors, however it is unlikely to include the facilities available in a CAD system such as zooming, pan, layer.

This thesis describes a PC-based interactive CAD system, for closed die forging design. This system includes the facilities for drawing the die geometry, simulation of the deformation process and die analysis under forming condition.

First of all, a commercial CAD system has been customized to accommodate the empirical guidelines for closed die forging design Then a Finite Element program FE has been developed based on the ngid plastic/viscoelastic formulation to simulate the metal flow. A mesh generation program has been developed as part of this system. The CAD system has been used as pie- and post processor for the mesh generation and the FE programs.

To overcome the problems encountered in forming processes, such as large deformation and displacements which cause certain computational problems, a rezoning algorithm has been developed.

An elastic/plastic FE program has been used for die analysis, the FE simulation results of the forming process are used to find out whether the analyzed die would sustain the forging load or not.

This metal flow simulation and die design process has been applied to two closed die forging examples, one in plane-steam condition and the other in asymmetric condition. The results were encouraging and in close agreement with the experiments.

Keywords:

Closed Die Forging, Metal Flow Simulation, Finite Element Analysis (FEA), CAD Customization, Die Design Optimization

Reference List:

Wallace, P.W., & Schey, J.A. (1967). Metal Flow in Forging: A Practical Study. The 8th Machine Tool Design and Research Conference, Birmingham.
Neuberger, F., & Mockel, L. (1961). Weikstattstechnik, Vol. 51.
Wick, C. (1982). Tool and Manufacturing Engineering Handbook. 4th Edition, Society of Manufacturing Engineers (SME).
German Standard DIN 7523 (1972).
British Standards BS 4114 (1967).
Raikar, A., Haque, I., & Jackson, J. (1987). An Empirical-Based Computer-Aided Design Procedure for Die Design Forging. Journal of Applied Metalworking, Vol. 4, No. 4.
Akgermann, N., Becker, J.R., & Altman, T. (1973). Preform Design in Closed Die Forging. Metallurgia and Metal Forming, Vol. 40, pp. 135-138.
Chamouarû, A. (1964). Estampage el Frappe. Dunod, Paris.
Biswas, S.K., & Rooks, B.W. (1975). Application of Modular Approach to Estimate Load and Energy in Closed Die Forging. Proceedings of the 13th International Machine Tool Design and Research Conference, Birmingham.
Knight, W.A., & Poll, C. (1982). Computer-Aided Product Design for Economic Forging. Computers in Engineering, Vol. 1, pp. 7-12.
Teterin, G.P., et al. (1966). Shape Difficulty Criteria for Forgings. Kuznechnuo-Shtamp, Proizv, Vol. 7.
Choi, S.H., & Dean, T.A. (1987). Computer-Aided Design of Die Block Layouts. International Journal of Machine Tools and Manufacture, Vol. 27, No. 1, pp. 91-163.
Altan, T., & Lahoti, G.D. (1979). Limitations, Applicability, and Usefulness of Different Methods in Analyzing Forming Problems. Annals of the CIRP, Vol. 28, pp. 473-483.
Altan, T., Henning, H.J., & Sabroff, A.M. (1970). The Use of Model Materials in Predicting Forming Loads in Metalworking. Transactions of the ASME, pp. 444-452.
Van Hoenacker, Y., & Dean, T.A. (1979). Approximate Method for the Calculation of Loads and General Flow Patterns when Forging Real Materials. The 20th International Machine Tool Design and Research Conference, Birmingham.
Hashmi, M.S., & Klemz, W.A. (1979). Closed Die Forging of Axisymmetric Shapes from Cylindrical Billets of Strain Hardening and Strain Rate Sensitive Materials: Experimental Results and Theoretical Predictions. The 20th International Machine Tool Design and Research Conference, Birmingham.
Chan, Y.K., Mulhneux, G., & Knight, W.A. (1979). Progress in the Computer-Aided Design and Manufacture of Hot Forging Dies. The 20th International Machine Tool Design and Research Conference, Birmingham.
Altan, T., & Fiorentino, F.J. (1971). Prediction of Loads and Stresses in Closed Die Forging. Journal of Engineering for Industry, pp. 477-486.
Toren, S., Ebbesen, J., Slutas, J., & Saetie, I. (1974). Die Life Estimation in Forging. The 15th International Machine Tool Design and Research Conference, Birmingham.
Altan, T., & Henning, H.J. (1972). Closed Die Forging of Round Shapes. Metallurgy and Metal Forming, Vol. 39, pp. 83-88.
Biswas, S.K., & Rooks, B.W. (1973). Application of a Computer Simulation Technique to Estimate Load and Energy in Axisymmetric Closed Die Forging. Proceedings of the 13th Machine Tool Design and Research Conference, Birmingham.
Knight, W.A., & Mullineaux, G. (1979). Estimation of the Centre of Loading for Forgings. International Journal of Machine Tool Design and Research, Vol. 19, pp. 181-193.
Altan, T., & Henning, H.J. (1984). Computer-Aided Design for Axisymmetric Forgings. International Journal of Machine Tool Design and Research, Vol. 24, No. 2, pp. 105-119.
Teterin, G.P., et al. (1966). Shape Difficulty Criteria for Forgings. Kuznechnuo-Shtamp, Proizv, Vol. 7.
Metals Handbook (1970). Forging and Casting, 8th Edition, American Society for Metals.
Shabaik, A. (1981). The Distinctions Between Various Constitutive Formulations Used to Simulate the Deformation of Metals. International Journal for Numerical Methods in Engineering.
Zienkiewicz, O.C. (1977). The Finite Element Method in Engineering Science. McGraw-Hill.
Kobayashi, S. (1984). Metal Forming and the Finite Element Method. Oxford University Press.
Hibbitt, Karlsson, & Sorensen Inc. (1985). ABAQUS: A General-Purpose Finite Element Code for Nonlinear Problems. User’s Manual.
Chenot, J.L. (1988). Adaptive Mesh Refinement in Finite Element Analysis of Metal Forming Processes. International Journal of Mechanical Sciences.