Preliminary research for the development of a hot forging die life prediction model /

by Grobaski, Thomas C.

The goal of this research was to provide a preliminary step into developing a complete forging die life model. The research involved analyzing the initial effects of (1) friction, (2) work-piece temperature, (3) die temperature, and (4) forging press stroke speed on effective die stresses, die surface temperatures, die/work-piece sliding velocities, die/work-piece contact pressures, and die surface temperatures were examined. To obtain the results the forging process was modeled (SolidEdge 3D Solid Modeling Software), simulated (MSC.Superforge Software), and statistically setup and examined using two-level full factorial design of experiments (Analyzed with Minitab & MS. Excel). The product reviewed was a 10inch diameter differential ring gear forged at the American Axle Manufacturing, North Tonawanda, New York forging plant. The 4 ring gear is used in the rear differentials for Ford and GM trucks. Approved: Bhavin Mehta Professor of Mechanical Engineering 5