13aa Cold Forging

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information about cold forging product development

Text of 13aa Cold Forging

  • ProcessandProductDevelopment

    ValveTappetColdforgingProcess

    AbdullahAnsari

  • INDEX Introduction

    NatureofProblem

    ExistingBlank&ForgingDieAnalysis

    ColdForgingStandard

    ExistingD2/d2 &l/dRatios

    CorrectiveActions

    Recalculations,ResultsOfRecalculations

    Trials&Decisions

    PreviousProcess&RevisedProcess

    ResultswithRevisedTooling&Conlusion

    SupportDuringDevelopment

  • INTRODUCTION

    The problem of head offsetting while cold forging of item R 70813 is observedin since new product development.

    To avoid the same several corrective actions [short method] were initiated suchas using flat ejector etc. but effectiveness of the actions taken was not 100%satisfactory. The results were not consistent.

    After all above it is concluded to analyze and redesign of cold forging tooling &process.

    While analyzing the same whatever the calculations, observations and theactions taken by undersigned are recorded here, which will be one guide line toattend this kind of problems in future.

    A.T.ANASRIDate:22.08.2000

  • NatureofProblem

    (TappetR70813)Whilecoldforging1st stageHeadDiameterofTappetgettingmoreoffsets&notgettingcontrolledafter

    severaladjustments.

  • ExistingBlank&ForgingDieanalysis .SizeofColdforgingblank:TotalLength=85mmOuterdiameter(d)=12.5mm .Sizeofcoldforgedpart:Headdiameter(D)=30mmHeadthickness=5.5mmTotallength=61mmODofstem=12.8&12.6mm .SizeofColdforgingDie:Lengthofdie=90mmLengthofblankoutsidethedie(l)=30mm

    (Fromflatface)

  • Coldforgingstandard

    Coldforgingstandardstatesthat:D2/d2 andl/dshouldnotexceed3.Where2isideal.

    InourcaseD=30mmd=12.5mml=30mm

  • D2/d2 =302/12.52 =5.76l/d=30/12.5=2.40 ByabovecalculationsitisnoticedthatvalueD2/d2 is

    exceeding thestandardandl/disalmostinrange. Sowemayconcludethataboveexceedingvalue is

    affectingtoforgedheaddiameteroffsetting.

    InlightofColdForgingStandardExistingD2/d2&l/dratios

  • Whattodonow???

    Correctiveactionplanned :Recalculate the die design as per coldforging standard. And manufacture thecold forging die as per new calculateddimensions.

  • RecalculationsasperColdforgingstandard

    D2/d2 = 2 ( as per standard )Hence D2/12.52 = 2D2 = 2 x 12.52

    D = 17.67mm.l of D will be 17.67x17.67x l x /4 = 12.5x12.5x30x /4

    l = 15.01mm

  • WhatRecalculationsIndicating!!!

    Recalculations indicating that the forging is not possible in one operation& it will need double operation. For second operation stepped blank willbe required, while first operation stepped blank will be produced.

    Forpreparingsteppedblankseparatedieisrequired

  • Trials.

    Fortrialssteppedblankispreparedbymachining.Whiletrialsformingpunchisused.

    Trialsaretakenwithsteppedblankon22.08.2000Resultsfoundsatisfactoryinallaspects.Head offsetting is very low & will not create anydefect while head turning.

    Dimensions are found consistent.Trials are successful.

  • WayForward.

    Basedonsuccessfultrials,diedesignedforfirstoperationforpreparingthesteppedblank(coldforging1st operation).

  • #PREVIOUSPROCESS

    Fig.Showsthe

    blankreadyfor

    forgingofR708

    13tappet.

    85

    12.5

  • 1 PREVIOUSPROCESS

    Fig.Showstheforgingdrawingof

    R70813tappet.

    Previouslythiswascreatedinsingle

    setting.

    30 12.8

    5

    40

    12.6

  • #REVISEDPROCESS

    Fig.Showsthe

    blankreadyfor

    producing

    steppedblank

    forforgingof

    R70813tappet.

    85

    12.5

  • 1 REVISEDPROCESS

    Fig.Showsthe

    steppedblank

    readyforfinish

    forgingofR70813

    tappet.

    12.6 12.5

    40

    17.7

    15

  • 30 12.8

    5

    40

    12.6

    2 REVISEDPROCESS

    Fig.ShowsthefinishforgingofR70813

    tappet.

    Nowitiscreatedinsecondstagefrom

    steppedblank.

  • DiedrawingforsteppedBlank

  • Resultswithrevisedtooling.

    Implemented the new tooling & monitored for 1000nos forcold forging 1st & 2nd operation.

    Noproblemwhilepreparingsteppedblank.I.e.1stoperation.

    Noproblemofheadformingwhile2nd operation.Improvedconsistencyindimensionswhilecoldforging2nd stage.

    Settingtimeforcoldforgingisreduced.Minimizesrejectionatcoldforgingdrastically.Hencereductioninwastage.

  • FINALCONCLUSION.

    The newly designed tooling is OK & Proven

    for production.05.11.2000

  • Mr.VRamgopalMr.M.GANAPATHY

    ForGivingAOpportunityToWorkOnSuchASpecialTask.

    Mr.S.C.SALVI&Mr.P.S.KULKARNITeammembers

    Acknowledgements

  • ThankYou

    abdullahta@gmail.com