Simulation of Cold Forging. - examples of applications from around the world - Dr. Gerhard H. Arfmann CPM GmbH, Herzogenrath

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1 Simulation of Cold Forging - examples of applications from around the world - Dr. Gerhard H. Arfmann CPM GmbH, Herzogenrath 1 CV Dr. Arfmann Till 1974 High School at Kreisgymnasium Halle, Halle Westfalen, Germany Electrical Engineering at Aachen University of Technology, Aachen, Germany Mechanical Engineering at Aachen Universtiy of Technology, Aachen, Germany Research at Institute of Metal Forming at University of Technology Aachen, Germany Since 1990 CEO of CPM GmbH, Herzogenrath, Germany Academic Degrees: 1981 Dipl.-Ing. (Electr. Eng.) 1983 Dipl.-Ing. (Mech. Eng.) 1999 Dr.-Ing. (Met. Forming) Memberships VDEh Association of Steel making Engineers VDE Association of Electric Engineers ICFG International Cold Forging Group DSV German Fastener Association (via CPM GmbH) GCFG German Cold Forging Group (via CPM GmbH) 2 1

2 History and Business of CPM GmbH 1997 Founded in 1987 by Professors and Engineers of Aachen University of Technology as part time business in Aachen 1990 Moving the company to Herzogenrath and run it as full time business 1992 Management buyout by Dr. Arfmann and Dr. Twickler Intensive Extending of the business in Europe, Brazil and India 2000 ff. Extension of business to Asia 2004 First Activities in China Simulation Sales Agencies: Japan, Korea, Taiwan, China, SE Asia, India, Turkey, Russia, UK, France, Spain, Italy, Brazil, Argentina, (Mexico) Focus of business: Customers/Partners: Research, Consulting, Simulation Companies from Hot and Cold Forging Machine, Tool, Material and other Suppliers to Forging Industry Universities 3 20 Years of simulation in Cold forming- What are the standard applications in industry? - Process design - Geometrical failure - Material flow - Tool design - Tool failure 4 2

3 Production of a shock absorber Conventional process 5 Production of a shock absorber Single stage process 6 3

4 Production of a shock absorber Simulation of the single stage process 7 Production of a shock absorber Simulation of the single stage process 8 4

5 Simulation of a cross Test of new processes 9 Simulation of a valve tappet Traditional process 10 5

6 Simulation of a valve tappet Traditional process 11 Simulation of a valve tappet New process 12 6

7 Simulation of a valve tappet New process 13 Simulation of a Brake Pisten traditionell process 14 7

8 Simulation of a Brake Pisten traditionell process 15 Simulation of a Brake Piston new process osen- 16 8

9 Simulation of a Brake Piston Comparison work needed 17 Simulation of a Brake Piston Since both processes need the same work (besides small differences in friction etc) the Osen process requires less load. The Osen process requires about 180 to while the backward extrusion requires 450 to. Comparison work needed 18 9

10 Production of an inner race Inner race process developement 19 Production of an inner race 1. forming 2. forming 20 10

11 Production of an inner race No sufficient filling (normal pressure on surface) 21 Production of an inner race No sufficient filling (normal pressure on surface) 22 11

12 Production of Cages Product 23 Production of Cages New process using osen technology 24 12

13 Production of Cages New process using osen technology 25 Production of a shock absorber body 26 13

14 Production of a shock absorber body New process using osen technology 27 Production of valve spring retainers Progression to produce a retainer 28 14

15 Production of valve spring retainers Premature tool failure 29 Production of valve spring retainers Premature tool failure 30 15

16 Production of valve spring retainers Premature tool failure 31 Production of valve spring retainers Premature tool failure 32 16

17 Production of valve spring retainers Premature tool failure 33 Production of a nut Premature tool failure 34 17

18 Production of a nut Premature tool failure 35 Production of a nut Premature tool failure 36 18

19 Production of a bolt Premature tool failure in station 4 37 Production of a bolt Premature tool failure in station

20 Production of a bolt Premature tool failure in station 4: old layout 39 Production of a bolt Premature tool failure in station 4: old layout 40 20

21 Production of a bolt Premature tool failure in station 4: old layout 41 Production of a bolt Premature tool failure in station 4: new design 42 21

22 Production of a bolt Premature tool failure in station 4: new design 43 Production of a bolt - tooling Design of a die 44 22

23 Production of a bolt - tooling Design of a die 45 Production of a bolt - tooling Pressure on die surface 46 23

24 Production of a bolt - tooling Tangential stress without pre-stressing 47 Production of a bolt - tooling Pre-stressing system design 48 24

25 Production of a bolt - tooling Tangential stress in the insert (with pre-stressing) 49 Production of a bolt - tooling Tangential stress in the insert (with pre-stressing) 50 25

26 Trust in eesy simulation Thank you for your attention Customers are happy to solve their daily problems with simulation 51 26

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