FEM simulation and experimental validation of flash-less cold forging for producing AUV propeller blade

H. M.T. Khaleed*, Z. Samad, M. A. Mujeebu, A. Badaruddin, I. A. Badruddin, A. B. Abdullah, N. J. Salman Ahmed

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

1 Citation (Scopus)


Manufacturing of the Autonomous Underwater Vehicle (AUV) is a challenge for researchers because of the hazardous ocean environment. The propeller is the most complex part in AUV because of its elaborately shaped blade designed to increase the thrust. The selection of the manufacturing process, flash-less cold forging die design and optimization of the work-piece are the major issues to reduce the overall cost of the propeller. Numerous investigations have been carried out in this area by many researchers using various tools and techniques. However, cold forging of complex geometries such as the propeller blade is still lacking. Moreover, volumetric analysis and optimization of work-piece have not been reported so far for complex geometries. In this work, the cold forging process is adopted to produce the propeller blade. Three-dimensional finite element (FE) analysis and experimental flash-less cold forging of aluminum blade of the AUV propeller is presented. The work-piece used is of AISI AL6061 and the die material is die steel (AISI D2).Based on the simulation results, the flash-less cold forging is successfully done on a 100 ton C-type machine.

Original languageEnglish
Pages (from-to)1-12
Number of pages12
JournalIranian Journal of Science and Technology - Transactions of Mechanical Engineering
Issue numberM1
Publication statusPublished - 2012


  • Autonomous under water vehicle
  • Cold forging
  • FEM
  • Flash-less
  • Under-filling

ASJC Scopus subject areas

  • Computational Mechanics
  • Mechanics of Materials
  • Mechanical Engineering


Dive into the research topics of 'FEM simulation and experimental validation of flash-less cold forging for producing AUV propeller blade'. Together they form a unique fingerprint.

Cite this