Simulation applications in cold forging production

Forging, one of the oldest methods of production, is a metal forming process that often preferred in today's industry. In forging process, workpiece is formed by being exposed to press forces between two dies or tools. In hot forging, many metallic parts may be produced in a wide range and can be processed in complex geometries. In warm forging, advantages like "the precision and material using of the hot forging and workability range and geometric shapes of the cold forging" comes together. In the cold forging process, metals which shows ductility at room temperature, can easily formed without being exposed to a pre-heating or intermediate-heating. Also, in cold forging process, high surface quality can be obtained and precise tolerances can be forged. Using of materials during production is higher than other forging process and this makes cold forging very advantageous in mass production. In this thesis, the rod part produced from 16MnCr5 material with cold forging process by a forging factory, is produced again in a simulation environment with a simulation software that using finite elements method, in accordance with rod part's real production conditions. Thereafter, based on these production conditions, by changing of production parameters like "press speed of cold forging, coefficient of friction between workpiece and dies, materials using in workpiece and temperature values of enviroment which part is produced", new cold forging simulations were designed with different production conditions. In conclusion of these studies, results obtained from simulations are examined and in this results, effects of production parameters changings to strain, stress, material flow speed, workpiece temperature and press forces were seen and analyzed.