Experimental and FEM Simulation Analysis of Closed-Die Forging Process on Companion Flange in the Driving Automotive System

The forging process is presented as a possible solution as it allows the production of parts with good surface finish and mechanical properties. In this paper, the new forging process for forming the Companion flange in the automotive driving system is proposed. The key technology of the new forging process is focused on the finish-forging design. The closed-die forging without a flash process for the finish-forging is proposed, by which the material utilization rate is enhanced greatly. The proper forming includes three steps: upsetting, performing, and finish forging. The 3D finite element method (FEM) for simulation of the forging process is also presented. In this study, the usage of finite element software has been applied to model a forming operation. Based on the simulation results, the parts are successfully done on a 1000 tons hot forging crank-stamping press. The experimental forged samples are observed in good conformity with the simulated models. The industrial application of new technology is shown, too