Automotive components are with extremely intricate profiles to serve its application. Explicitly, a constant velocity joint’s outer race (TULIP housing) geometry is very complicated, difficult to be manufactured due to its high requirement of precision. Traditional hot and cold metal forming methods have their own limitations to produce such a complex shaped product; precision hot forging is exceedingly multifaceted with many variables while cold forging is not applicable to materials with limited formability. Therefore multistage forging may be advantageous to produce complex shapes. The particular process presented in this paper is the method used to form an intricate shape in stage by stage process i.e. warm pre-forge, warm backward extrusion and calibration draw or cold sizing. Near net shape forging of a tulip housing is numerically analyzed using rigid-plastic finite element method; an in-depth understanding of operation was obtained. To prevent fracture and surface defects in the final stage, a damage criterion was applied to the cold sizing process where the occurrence of defects is high. A real time experiment is conducted in order to test the reliability of FE method and sensitivity of damage model in predicting defects as to avoid them on the forged final product. The results from this numerical analysis illustrate the powerful application of modern FEA package like DEFORM-3D for complex and large scale deformation process.

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Tue, 19/04/2011 - 21:09