Optimizing Cold Forging Designs Through FEA and Progression Design Software
In this study, the manufacturing of a socket head cap screw is reviewed. Three alternative progression designs, each using a different starting wire diameter, are developed using NAGFORM forging sequence design software. The three progression designs are then simulated using NAGSIM.2D / NAGSIM.3D finite element analysis (FEA) simulation software to predict forging loads, strain distribution within the forged part and stresses in selected tooling components.
The simulation results demonstrate that one of the proposed forging sequences has the potential to significantly reduce manufacturing costs compared with the other alternatives, provided that the required forging equipment is available and the part is heat treated after forging. The results also demonstrate that the optimal progression design may vary depending on the strength and material properties of the material being formed