Work-piece optimization and thermal analysis for flash-less cold forging of AUV propeller hubs — FEM simulation and experiment

In this paper three-dimensional FEM based work-piece optimization and thermal analysis for flash-less cold forging of aluminum front and back hubs of an Autonomous Underwater Vehicle (AUV) propeller is presented. The work-piece used is of AISI AL6061 and the die material is die steel (AISI D2). For...

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Bibliographic Details
Published in:Journal of manufacturing processes 2011, Vol.13 (1), p.41-49
Main Authors: Khaleed, H.M.T., Samad, Z., Othman, A.R., Mujeebu, M.A., Abdullah, A.B., Zihad, M.M.
Format: Article
Language:English
Subjects:
Applied sciences
Autonomous underwater vehicles
Computer simulation
Design optimization
Exact sciences and technology
Finite element analysis
Forging
Forging and extrusion
Forming
Metals. Metallurgy
Optimization
Production techniques
Propellers
Studies
Thermal energy
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Summary:In this paper three-dimensional FEM based work-piece optimization and thermal analysis for flash-less cold forging of aluminum front and back hubs of an Autonomous Underwater Vehicle (AUV) propeller is presented. The work-piece used is of AISI AL6061 and the die material is die steel (AISI D2). For front and back hubs, five cases of work-pieces of varying dimensions are simulated to obtain the optimum work-piece in terms of flash and under-filling and the optimization is verified through thermal analysis. Based on the simulation results, the flash-less cold forging is successfully done on a 100 ton C-type machine. The experimental forged samples are observed in good conformity with the simulated models.
ISSN:1526-6125
2212-4616
DOI:10.1016/j.jmapro.2010.10.003