Optimum Flash-Less Cold Forging Process For Auv Propeller Fabrication With Fem
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Date
2010-01
Authors
M Tandur, Khaleed Hussain
Journal Title
Journal ISSN
Volume Title
Publisher
Universiti Sains Malaysia
Abstract
The selection of the manufacturing process, flash-less cold forging die design and optimization of work-piece are the major issues to reduce the overall cost of the propeller. Substantial investigations have been carried out on this area, by many researchers using various tools and techniques. However, cold forging of complex geometries such as propeller hub and blade is still lacking. Moreover, volumetric analysis and optimization of work-piece have not been reported so far for complex geometries. In this thesis, the cold forging process has been adopted to produce the propeller hub and blade. Three-dimensional finite element (FE) analysis and experimental flash-less cold forging of aluminum hubs and blade of AUV propeller was presented. The work-piece used was of AISI AL6061 and the die material was die steel (AISI D2). Based on the simulation results, the flash-less cold forging was successfully done on a 100 ton C-type machine. Among the five cases of work-pieces studied, optimum work-pieces were obtained for no under filling and minimum flash for the hubs and blade. The load required for forging and effective stresses in the die were significantly reduced for hubs and blade. With no under filling, the percentage of 13.72% was obtained for simulation and 4.54% was obtained for experiment. The propeller was tested for bending and concluded that the produced propeller was suitable for AUV. In the present study, the modularized AUV propeller hubs and the blade were produced successfully by cold forging process. Flash-less cold forging for complex profile, detailed volumetric analysis, work-piece optimization and handling of complex and thin geometries were the remarkable contributions in this work.
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Keywords
Optimum flash-less cold forging process , for auv propeller fabrication with fem