Title: Precision forging of alternator poles by flow control method

Authors: Cheng Yang; Shengdun Zhao

Addresses: School of Metallurgical Engineering, Xi'an University of Architecture and Technology, Xi'an, China ' School of Mechanical Engineering, Xi'an Jiaotong University, Xi'an, China

Abstract: Alternator poles have been conventionally produced by the multi-stage forging processes. As an alternative, several one-stage precision forging processes of alternator poles are put forward in this paper. The influence of different designs on metal flow and load requirements is examined through finite element simulation and experiments. It is shown that the design which has a moveable mandrel supported by a back force is useful to control the metal flow in the die cavity and to reduce the forging load. Well-shaped product can be forged successfully using a lower forging load by flow control method than that of conventional precision forging.

Keywords: precision forging; flow control; alternator poles; finite element method; FEM; simulation; moveable mandrel; back force; metal flow; die cavity; forging load.

DOI: 10.1504/IJMPT.2015.068557

International Journal of Materials and Product Technology, 2015 Vol.50 No.3/4, pp.366 - 378

Accepted: 14 Oct 2014
Published online: 05 Apr 2015 *

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