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

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.