FEM analysis and experimental validation of flashless cold forging of autonomous underwater vehicle hubs

Abstract

In this paper three-dimensional FEM analysis and experimental flashless cold forging of aluminum front and back hubs of Autonomous Underwater Vehicle (AUV) propeller is presented. The rigid-plastic finite element simulation is performed using DEFORM F-3V6.0, to estimate the optimum load required for the flashless cold forging. The complex profiles of the hubs are modeled using SOLIDWORKS SP4.02007 which is used for the modeling of work-piece and die-punch assembly as well. The work-piece used is of AISI AL6061 and the die material is die steel (AISI D2). The process is optimized to form the propeller back and front hubs. For both the models, three workpieces with different aspect ratios are selected and investigated to obtain the optimum workpiece that gives flashless cold forging with acceptable underfilling. Based on the simulation results, the flash-less cold forging is successfully done on a 100 ton C-type machine. The experimental forged samples are observed in good conformity with the simulated models.