Flash-less cold forging and temperature distribution in forged autonomous underwater vehicle hubs using fem analysis and experimental validation

H. M.T. Khaleed, Z. Samad, A. R. Othman, M. A. Mujeebu, A. B. Abdullah, N. J.S. Ahmed, M. M. Zihad

Research output: Contribution to journalArticle

2 Citations (Scopus)


In this paper three-dimensional FEM analysis and experimental flash less cold forging and temperature distribution 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 flash less 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 work pieces with different aspect ratios are selected and investigated to obtain the optimum work piece that gives flash less cold forging with acceptable under filling. 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.

Original languageEnglish
Pages (from-to)291-299
Number of pages9
JournalInternational Journal of Mechanical and Materials Engineering
Issue number2
Publication statusPublished - Aug 2011



  • Auv propeller
  • Flash less cold forging
  • Front and back hubs
  • Under filling
  • Work-piece optimization

ASJC Scopus subject areas

  • Materials Science(all)
  • Mechanics of Materials
  • Mechanical Engineering

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