Production of cold forging eccentric parts by new die designs and production prototype for horizontal cold forging presses

For the last decade, there is an an increase in the demand for new special fasteners in automotive, aerospace and defence industries. These needs are generally done to provide alternative solutions by weight reduction, easier assembly processes of fasteners and maintaining vibration and fatigue resistance. Eccentirc bolts can be shown as an example for these fasteners. These kind of metal fasteners are generally produced by machining, hot and warm forging. In this thesis, a special type of die system will be designed and produced for the manufacturability of an eccentric bolt by cold forging. CAE analysis program is used for examining the plastic deformation properties of the asymmetric bolt, analyzing the motion of the die mechanism, identifying the geometrical dimensions, mechanical properties of the final product obtained and getting a know-how of its manufacturability. "Simufact Forming" software is used for forming analysis. 20MnB4 wire material is used to ensure the mechanical properties of the final product in manufacturing stages. As conclusion, die designs and cold forging simulations for the asymmetric bolt have been completed successfully with the proposed die mechanism. Furthermore, the experimental and the simulation results of the product showed consistency; the manufacturability of the asymmetric bolt by 20MnB4 steel wire is identified. In addition, a utility model application to the Turkish Patent Instutition has been made with the application number of 2016/06010 for the completed model and the die system.